Chevrolet - Civic Sedan - Workshop Manual - 1995 - 1995

Factory Workshop Manual Make Honda Model Civic Sedan Engine and year L4-1.5L SOHC (16 valve) (1995) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Locations Power Door Lock Control Module: Locations Front Of Driver's Door Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof/Moonroof Relay <--> [Sunroof / Moonroof Relay] > Component Information > Locations > Moonroof Close Relay Sunroof/Moonroof Relay: Locations Moonroof Close Relay Behind Left Side Of Dash Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof/Moonroof Relay <--> [Sunroof / Moonroof Relay] > Component Information > Locations > Moonroof Close Relay > Page 11 Sunroof/Moonroof Relay: Locations Moonroof Open Relay Behind Left Side Of Dash Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Locations ABS Main Relay: Locations Fuse/Relay Information-Under-hood ABS Fuse/Relay Box Right Side Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Brake Fluid Pump Relay > Component Information > Locations Brake Fluid Pump Relay: Locations Fuse/Relay Information-Under-hood ABS Fuse/Relay Box Right Side Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations Electronic Brake Control Module: Locations Right Side Of Trunk Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 22 Electronic Brake Control Module: Description and Operation The main function section of the control unit performs calculations on the basis of the signals from each speed sensor. It controls the operation of the anti-lock brake system by putting the solenoid valves in the modulator unit into action for each front brake and for the two rear brakes. The sub-function section gives driving signals to the pump motor and also gives self-diagnosis signals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 23 Electronic Brake Control Module: Service and Repair Fig. 90 Control Unit Replacement Refer to Fig. 90 when replacing the control unit. 1. Remove right side trunk trim panel. 2. Disconnect control unit connectors. 3. Remove control unit mounting bolts, then the control unit. When control unit mounting bolts are removed, the control unit's memory is cleared. 4. Reverse procedure to install. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Fail Safe Relay, ABS / Traction Control > Component Information > Locations > Front Fail Safe Relay: Locations Front Right Side Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Fail Safe Relay, ABS / Traction Control > Component Information > Locations > Front > Page 28 Fail Safe Relay: Locations Rear Right Side Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Right Rear Corner Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 33 Radiator Cooling Fan Motor Relay: Testing and Inspection Fig. 10 Cooling Fan Relay Terminal Identification 1. Disconnect electrical connector and remove relay. 2. Connect ohmmeter between relay terminals A and B, Fig. 10. 3. Meter should indicate no continuity. 4. Connect battery voltage across terminals C and D. 5. With relay energized, ohmmeter should indicate continuity between terminals A and B. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations Cruise Control Module: Locations Left Kick Panel - Photo 53 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations Blower Motor Relay: Locations Right Rear Corner Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 42 Blower Motor Relay: Testing and Inspection Relay Test - There should be continuity between the C and D terminals. - There should be continuity between the A and B terminals when power and ground are connected to the C and D terminals. - There should be no continuity when power is disconnected. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Photo 19 - A/C Pressure Switch Left Front Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 46 Compressor Clutch Relay: Testing and Inspection Relay Test - There should be continuity between the C and D terminals. - There should be continuity between the A and B terminals when power and ground are connected to the C and D terminals. - There should be no continuity when power is disconnected. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Photo 19 Condenser Fan Motor Relay: Locations Photo 19 Photo 19 - A/C Pressure Switch Left Front Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Photo 19 > Page 51 Condenser Fan Motor Relay: Locations Photo 31 Right Rear Corner Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Page 52 Condenser Fan Motor Relay: Testing and Inspection Relay Test - There should be continuity between the C and D terminals. - There should be continuity between the A and B terminals when power and ground are connected to the C and D terminals. - There should be no continuity when power is disconnected. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions Control Module HVAC: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 57 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 58 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 59 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 60 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 61 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 62 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 63 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 64 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 65 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 66 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 67 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 68 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 69 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 70 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 71 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 72 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 73 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 74 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 75 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 76 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 77 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 78 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 79 Control Module HVAC: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 80 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 81 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 82 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 83 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 84 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 85 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 86 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 87 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 88 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 89 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 90 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 91 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 92 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 93 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 94 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 95 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 96 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 97 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 98 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 99 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 100 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 101 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 102 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 103 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 104 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 105 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations Daytime Running Lamp Control Unit: Locations Daytime Running light Relay/Control Unit Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations > Page 110 Daytime Running Lamp Control Unit: Testing and Inspection Input Test Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations > Page 111 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Behind Dash, Right Of Steering Column Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Locations Hazard Flasher Relay: Locations Behind Left Side Of Dash Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Behind Left Side Of Dash - Photo 62 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Locations Turn Signal Relay: Locations Behind Left Side Of Dash Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Electrical Load Detector (ELD) Unit Relay Box: Locations Electrical Load Detector (ELD) Unit Bottom Of Under-hood Fuse/Relay Box Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Electrical Load Detector (ELD) Unit > Page 129 Relay Box: Locations Under-Dash Fuse/Relay Box Photo Behind Left Side Of Dash Under Dash Fuse/Relay Box Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Electrical Load Detector (ELD) Unit > Page 130 Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Electrical Load Detector (ELD) Unit > Page 131 Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 2 Of 3) Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 3 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Electrical Load Detector (ELD) Unit > Page 132 Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 3 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Electrical Load Detector (ELD) Unit > Page 133 Relay Box: Locations Under-Hood ABS Fuse/Relay Box Photo Right Side Of Engine Compartment Fuse/Relay Information-Under-hood ABS Fuse/Relay Box Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Electrical Load Detector (ELD) Unit > Page 134 Fuse/Relay Information-Under-hood ABS Fuse/Relay Box Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Electrical Load Detector (ELD) Unit > Page 135 Relay Box: Locations Under-Hood Fuse/Relay Box Photo Right Rear Corner Of Engine Compartment Under-Hood Fuse/Relay Box Fuse/Relay Information-Under-hood Fuse/Relay Box (Part 1 Of 2) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Electrical Load Detector (ELD) Unit > Page 136 Fuse/Relay Information-Under-hood Fuse/Relay Box (Part 1 Of 2) Fuse/Relay Information-Under-hood Fuse/Relay Box (Part 2 Of 2) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Under-Dash Fuse/Relay Box Relay Box: Application and ID Under-Dash Fuse/Relay Box Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 1 Of 3) Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Under-Dash Fuse/Relay Box > Page 139 Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 2 Of 3) Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 3 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Under-Dash Fuse/Relay Box > Page 140 Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 3 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Under-Dash Fuse/Relay Box > Page 141 Relay Box: Application and ID Under-Hood ABS Fuse/Relay Box Fuse/Relay Information-Under-hood ABS Fuse/Relay Box Fuse/Relay Information-Under-hood ABS Fuse/Relay Box Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Under-Dash Fuse/Relay Box > Page 142 Relay Box: Application and ID Under-Hood Fuse/Relay Box Fuse/Relay Information-Under-hood Fuse/Relay Box (Part 1 Of 2) Fuse/Relay Information-Under-hood Fuse/Relay Box (Part 1 Of 2) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Under-Dash Fuse/Relay Box > Page 143 Fuse/Relay Information-Under-hood Fuse/Relay Box (Part 2 Of 2) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations Body Control Module: Locations Rear Of Under-dash Fuse/Relay Box Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 151 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 152 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 153 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 154 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 155 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 156 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 157 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 158 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 159 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 160 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 161 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 162 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 163 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 164 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 165 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 166 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 167 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 168 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 169 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 170 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 171 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 172 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 173 Body Control Module: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 174 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 175 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 176 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 177 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 178 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 179 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 180 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 181 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 182 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 183 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 184 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 185 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 186 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 187 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 188 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 189 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 190 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 191 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 192 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 193 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 194 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 195 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 196 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 197 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 198 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 199 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors Engine Control Module: Technical Service Bulletins Emissions - OBD II DTC's And Associated Monitors 03-020 April 2, 2010 Applies To: All OBD II-equipped models except Passport OBD II DTCs and Their Associated Monitors (Supersedes 03-020, dated March 29, 2003, to revise the information marked by the black bars and asterisks) *REVISION SUMMARY Numerous DTCs were added. Refer to the list for details.* Following is a list of all OBD II DTCs and their associated monitors for all Honda automobiles with OBD II. No one model has every DTC in the list. DTC P0AA6 thru P0A9E Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 204 DTC P0A94 thru P0157 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 205 DTC P0158 thru P0400 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 206 DTC P0401 thru P0562 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 207 DTC P0563 thru P0748 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 208 DTC P0750 thru P0977 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 209 DTC P0979 thru P1193 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 210 DTC P1253 thru P1459 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 211 DTC P1486 thru P1585 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 212 DTC P1586 thru P1678 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 213 DTC P1679 thru P1860 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 214 DTC P1861 thru P2238 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 215 DTC P2240 thru U0073 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 216 DTC U0100 thru U1288 Disclaimer Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 217 Engine Control Module: Locations Right Kick Panel Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 220 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 221 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 222 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 223 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 224 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 225 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 226 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 227 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 228 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 229 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 230 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 231 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 232 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 233 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 234 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 235 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 236 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 237 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 238 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 239 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 240 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 241 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 242 Engine Control Module: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 243 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 244 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 245 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 246 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 247 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 248 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 249 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 250 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 251 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 252 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 253 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 254 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 255 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 256 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 257 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 258 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 259 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 260 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 261 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 262 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 263 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 264 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 265 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 266 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 267 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 268 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 269 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 270 Engine Control Module: Description and Operation PURPOSE The engine control module takes the inputs from the various sensors and signals to manage the fuel injection, timing control and ignition. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics Engine Control Module: Component Tests and General Diagnostics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 273 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 274 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 275 NOTE: When there is no code stored, the MIL will stay on if the service check connector is jumped. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations PGM-FI Main Relay: Locations The PGM-FI relay is located under the left side of the dash. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions PGM-FI Main Relay: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 281 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 282 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 283 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 284 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 285 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 286 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 287 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 288 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 289 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 290 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 291 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 292 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 293 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 294 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 295 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 296 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 297 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 298 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 299 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 300 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 301 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 302 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 303 PGM-FI Main Relay: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 304 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 305 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 306 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 307 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 308 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 309 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 310 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 311 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 312 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 313 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 314 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 315 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 316 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 317 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 318 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 319 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 320 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 321 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 322 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 323 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 324 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 325 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 326 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 327 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 328 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 329 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 330 PGM-FI Main Relay: Description and Operation PURPOSE/OPERATION The PGM-FI main relay actually contains two individual relays. The relay is located at the left side of the cowl. One relay is energized whenever the ignition is on, which supplies the battery voltage to the ECM, power to the fuel injectors, and power for the second relay. The second relay is energized for 2 seconds when the ignition is switched on, and when the engine is running, to supply power to the fuel pump. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 331 PGM-FI Main Relay: Testing and Inspection NOTE: If the car starts and continues to run, the PGM-FI main relay is OK. 1. Remove the PGM-FI main relay. 2. Attach the battery positive terminal to the No. 6 terminal and the battery negative terminal to the No. 8 terminal of the PGM-FI main relay. Then check for continuity between the No. 5 terminal and No. 7 terminal of the PGM-FI main relay. ^ If there is continuity, go on to step 3. ^ If there is no continuity, replace the relay and retest. 3. Attach the battery positive terminal to the No. 5 terminal and the battery negative terminal to the No. 2 terminal of the PGM-FI main relay. Then check that there is continuity between the No. 1 terminal and No. 3 terminal of the PGM-FI main relay. ^ If there is continuity, go on to step 4. ^ If there is no continuity, replace the relay and retest. 4. Attach the battery positive terminal to the No. 3 terminal and the battery negative terminal to the No. 8 terminal of the PGM-FI main relay. Then check that there is continuity between the No. 5 terminal and No. 7 terminal of the PGM-FI main relay. ^ If there is continuity, the relay is OK. ^ If there is no continuity, replace the relay and retest. Main Relay And Harness Inspection Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 332 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 333 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 340 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 341 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 342 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 343 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 344 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 345 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 346 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 347 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 348 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 349 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 350 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 351 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 352 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 353 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 354 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 355 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 356 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 357 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 358 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 359 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 360 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 361 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 362 Fuel Pump Relay: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 363 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 364 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 365 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 366 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 367 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 368 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 369 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 370 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 371 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 372 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 373 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 374 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 375 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 376 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 377 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 378 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 379 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 380 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 381 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 382 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 383 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 384 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 385 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 386 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 387 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 388 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 389 Fuel Pump Relay: Connector Views For Connector Views refer to "Powertrain Management : Diagrams". Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 390 Fuel Pump Relay: Description and Operation PURPOSE/OPERATION The Programed Fuel Injection (PGM-FI) Main Relay actually contains two individual Relays. This Relay is located at the left side of the Cowl. One Relay is energized whenever the Ignition is "ON" which supplies the Battery voltage to the Engine Control Module (ECM), power to the Fuel Injectors, and power for the second Relay. The second Relay is energized for two seconds when the Ignition is switched "ON", and when the Engine is running, to supply power to the Fuel Pump. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 391 Fuel Pump Relay: Testing and Inspection NOTE: If the car starts and continues to run, the PGM-FI main relay is OK. 1. Remove the PGM-FI main relay. 2. Attach the battery positive terminal to the No. 6 terminal and the battery negative terminal to the No. 8 terminal of the PGM-FI main relay. Then check for continuity between the No. 5 terminal and No. 7 terminal of the PGM-FI main relay. - If there is continuity, go on to step 3. - If there is no continuity, replace the relay and retest. 3. Attach the battery positive terminal to the No. 5 terminal and the battery negative terminal to the No. 2 terminal of the PGM-FI main relay. Then check that there is continuity between the No. 1 terminal and No. 3 terminal of the PGM-FI main relay. - If there is continuity, go on to step 4. - If there is no continuity, replace the relay and retest. 4. Attach the battery positive terminal to the No. 3 terminal and the battery negative terminal to the No. 8 terminal of the PGM-FI main relay. Then check that there is continuity between the No. 5 terminal and No. 7 terminal of the PGM-FI main relay. - If there is continuity, the relay is OK. - If there is no continuity, replace the relay and retest. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 392 FLOWCHART PART 1 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 393 FLOWCHART PART 2 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations PGM-FI Main Relay: Locations The PGM-FI relay is located under the left side of the dash. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions PGM-FI Main Relay: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 399 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 400 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 401 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 402 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 403 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 404 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 405 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 406 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 407 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 408 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 409 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 410 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 411 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 412 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 413 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 414 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 415 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 416 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 417 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 418 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 419 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 420 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 421 PGM-FI Main Relay: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 422 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 423 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 424 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 425 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 426 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 427 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 428 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 429 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 430 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 431 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 432 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 433 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 434 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 435 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 436 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 437 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 438 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 439 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 440 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 441 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 442 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 443 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 444 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 445 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 446 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 447 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 448 PGM-FI Main Relay: Description and Operation PURPOSE/OPERATION The PGM-FI main relay actually contains two individual relays. The relay is located at the left side of the cowl. One relay is energized whenever the ignition is on, which supplies the battery voltage to the ECM, power to the fuel injectors, and power for the second relay. The second relay is energized for 2 seconds when the ignition is switched on, and when the engine is running, to supply power to the fuel pump. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 449 PGM-FI Main Relay: Testing and Inspection NOTE: If the car starts and continues to run, the PGM-FI main relay is OK. 1. Remove the PGM-FI main relay. 2. Attach the battery positive terminal to the No. 6 terminal and the battery negative terminal to the No. 8 terminal of the PGM-FI main relay. Then check for continuity between the No. 5 terminal and No. 7 terminal of the PGM-FI main relay. ^ If there is continuity, go on to step 3. ^ If there is no continuity, replace the relay and retest. 3. Attach the battery positive terminal to the No. 5 terminal and the battery negative terminal to the No. 2 terminal of the PGM-FI main relay. Then check that there is continuity between the No. 1 terminal and No. 3 terminal of the PGM-FI main relay. ^ If there is continuity, go on to step 4. ^ If there is no continuity, replace the relay and retest. 4. Attach the battery positive terminal to the No. 3 terminal and the battery negative terminal to the No. 8 terminal of the PGM-FI main relay. Then check that there is continuity between the No. 5 terminal and No. 7 terminal of the PGM-FI main relay. ^ If there is continuity, the relay is OK. ^ If there is no continuity, replace the relay and retest. Main Relay And Harness Inspection Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 450 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 451 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions Ignition Control Module: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 458 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 459 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 460 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 461 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 462 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 463 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 464 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 465 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 466 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 467 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 468 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 469 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 470 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 471 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 472 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 473 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 474 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 475 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 476 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 477 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 478 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 479 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 480 Ignition Control Module: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 481 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 482 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 483 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 484 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 485 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 486 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 487 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 488 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 489 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 490 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 491 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 492 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 493 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 494 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 495 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 496 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 497 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 498 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 499 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 500 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 501 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 502 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 503 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 504 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 505 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 506 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 507 Ignition Control Module: Connector Views For Connector Views refer to "Powertrain Management : Diagrams". Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Page 508 Ignition Control Module: Testing and Inspection NOTE: Perform an input test for the ignition control module (ICM) after finishing the fundamental tests for the ignition system and the fuel and emissions systems. The tachometer should operate normally. 1. Remove the distributor ignition cap, the distributor ignition rotor, and the leak cover. 2. Disconnect the BLK/YEL, WHT/BLU, YEL/GRN, and BLU wires from the ICM. 3. Turn the ignition switch ON. Check for voltage between the BLK/YEL wire and body ground. There should be battery voltage. ^ If there is no battery voltage, check the BLK/YEL wire between the ignition switch and the ICM. ^ If there is battery voltage, go to step 4. 4. Turn the ignition switch ON. Check for voltage between the WHT/BLU wire and body ground. There should be battery voltage. ^ If there is no battery voltage, check: Ignition coil. - WHT/BLU wire between the ignition coil and the ICM. ^ If there is battery voltage, go to step 5. 5. Check the YEL/GRN wire between the ECM and the ICM. 6. Check the BLU wire between the tachometer and the ICM. 7. If all tests are normal, replace the ICM. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Service and Repair > Removal Ignition Control Module: Service and Repair Removal 1. Disconnect the 2-P and 8-P connectors from the distributor. 2. Disconnect the ignition wires from the distributor ignition cap. 3. Remove the distributor mounting bolts, then remove the distributor from the cylinder bead. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Service and Repair > Removal > Page 511 Ignition Control Module: Service and Repair Installation 1. Coat a new 0-ring with engine oil, then install it. 2. Slip the distributor into position. NOTE: The lugs on the end of the distributor and its mating grooves in the camshaft end are both offset to eliminate the possibility of installing the distributor 180° out of time. 3. Install the mounting bolts and tighten them temporarily. 4. Connect the 2-P and 8-P connectors to the distributor. 5. Connect the ignition wires as shown. 6. Set the timing with a timing light. 7. After setting the timing, tighten the mounting bolts. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Service and Repair > Removal > Page 512 Ignition Control Module: Service and Repair Overhaul Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Service and Repair > Removal > Page 513 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Service and Repair > Removal > Page 514 Ignition Control Module: Service and Repair Reassembly Reassemble the distributor in the reverse order of disassembly. 1. Install the distributor ignition rotor, then turn it so that it faces in the direction shown (Toward the No. 1 cylinder). 2. Slip the thrust washer and coupling onto the shaft. 3. Check that the distributor ignition rotor is still pointing toward the No. 1 cylinder, then align the index mark on the distributor ignition housing with the index mark on the coupling. 4. Drive in the pin and secure it with the pin retainer. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module: Locations Right Side Of Driver's Footwell Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 519 Air Bag Control Module: Service and Repair 1. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. 2. Disconnect battery negative cable, then positive cable. 3. Pull down carpeting from both sides of front console and remove harness protector. 4. Disconnect SRS control unit connector. 5. Remove four SRS control unit mounting bolts, then control unit from vehicle. 6. Reverse procedure to install, noting the following: a. Tighten attaching bolts to specifications. b. After completing installation, place ignition switch in On position. SRS indicator lamp should be illuminated for approximately six seconds, then lamp should turn off. If lamp remains illuminated or does not illuminate, a problem in the SRS is indicated. 7. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Behind Left Side Of Dash Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection > Hitachi Starters Starter Relay: Testing and Inspection Hitachi Starters 1. Remove and disconnect starter relay. Fig. 5 Starter Relay Terminal Locations 2. Apply battery voltage to C and D terminals of relay, Fig. 5. 3. Check continuity between A and B terminals of relay. Continuity should exist. 4. Disconnect battery voltage. There should be no continuity between A and B terminals of relay. 5. If relay does not operate as specified, replace relay. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection > Hitachi Starters > Page 526 Starter Relay: Testing and Inspection Mitsuba Starters 1. Remove and disconnect starter relay. Fig. 10 Starter Relay Terminal Locations 2. Apply battery voltage to C and D terminals of relay, Fig. 10. 3. Check continuity between A and B terminals of relay. Continuity should exist. 4. Disconnect battery voltage. There should be no continuity between A and B terminals of relay. 5. If relay does not operate as specified, replace relay. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection > Hitachi Starters > Page 527 Starter Relay: Testing and Inspection Nippondenso Starters 1. Remove and disconnect starter relay. Fig. 13 Starter Motor Terminal Locations 2. Apply battery voltage to C and D terminals of relay, Fig. 13. 3. Check continuity between A and B terminals of relay. Continuity should exist. 4. Disconnect battery voltage. There should be no continuity between A and B terminals of relay. 5. If relay does not operate as specified, replace relay. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Shift Interlock Control Module > Component Information > Locations Shift Interlock Control Module: Locations Behind Left Side Of Dash Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Heated Glass Element Relay: Locations Right Rear Corner Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Rear Defogger Relay > Component Information > Locations Rear Defogger Relay: Locations Right Rear Corner Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations Power Window Relay: Locations Behind Left Side Of Dash Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Open/Close Switch Sunroof / Moonroof Switch: Locations Open/Close Switch Center Rear Of Roof Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Open/Close Switch > Page 549 Sunroof / Moonroof Switch: Locations Tilt/Close Switch Center Rear Of Roof Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations Brake Fluid Level Sensor/Switch: Locations Left Rear Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 554 Brake Fluid Level Sensor/Switch: Description and Operation The brake system indicator light comes ON to alert the driver that the parking brake is applied, or that the brake fluid level is low. It also comes ON as a bulb test when the engine is cranked. With the ignition switch in ON (II) or START (III), voltage is applied through fuse 15 to the brake system light. If the brake fluid level is low, the brake fluid level switch closes, providing ground to the circuit. The brake system light then comes ON, alerting the driver to a low brake fluid level in the brake master cylinder. (Check brake pad wear before adding fluid.) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Description and Operation Brake Fluid Pressure Sensor/Switch: Description and Operation The pressure switch monitors the pressure accumulation in the accumulator and is turned off when the pressure becomes lower than a prescribed level. When the pressure switch is turned off, the switching signal is sent to the control unit. Upon receiving the signal, the control unit activates the pump motor relay to operate the motor. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Parking Brake Switch Parking Brake Warning Switch: Locations Parking Brake Switch Below Rear Console Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Parking Brake Switch > Page 562 Parking Brake Warning Switch: Locations Parking Pin Switch Below Center Console Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Front Wheel Speed Sensor: Locations Front Behind Left Front Wheel (Right Similar) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Front > Page 567 Wheel Speed Sensor: Locations Rear Behind Left Rear Wheel (Right Similar) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 568 Wheel Speed Sensor: Description and Operation WHEEL SPEED SENSOR The speed sensor is a non-contact type which detects the rotating speeds of the wheel. It is composed of a permanent magnet and coil. When the gear pulsers at each wheel turn, the magnetic coil in the speed sensor alternates, generating voltages with frequency in proportion to wheel rotating speed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Testing and Inspection > Toothed Ring Wheel Speed Sensor: Testing and Inspection Toothed Ring INSPECTION OF THE TOOTHED RING 1. Check the front and rear pulser for chipped or damaged teeth. 2. Measure the air gap between the wheel sensor and pulser all the way around while rotating the pulser. Standard: 0.4 - 1.0 mm (0.02 - 0.04 inch) NOTE: If the gap exceeds 1.0 mm (0.04 inch), the probability is a distorted suspension arm which should be replaced. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Testing and Inspection > Toothed Ring > Page 571 Wheel Speed Sensor: Testing and Inspection Wheel Speed Sensor TESTING THE WHEEL SPEED SENSOR 1. Check pulser for chipped or damaged teeth and replace as necessary. Fig. 82 Measureing Front Speed Sensor Air Gap 2. Measure air gap between sensor and pulser all the way around while rotating driveshaft by hand, Fig. 82. If gap exceeds its maximum specification at any point, the knuckle is most likely distorted and should be replaced. Air gap should be 0.016-0.039 inches. WHEEL SENSOR SIGNAL CONFIRMATION 1. With ignition switch off, disconnect 6-P inspection connector from connector cover on crossmember under passenger seat and connect it to anti-lock brake checker tool Nos. 07HAJ-SG0010A or 07HAJ-SG0010B, or equivalents. 2. Raise and support vehicle so all four wheels are off ground. 3. Turn ignition switch to on position, then turn mode selector switch on anti-lock brake checker to 0. 4. With transaxle in Neutral position, rotate each wheel at least one revolution per second and confirm that its respective monitor light on the checker blinks as wheel is rotating. Rotating wheel too slowly will produce only weak blinks of monitor lights. Perform tests in shaded area, as monitor lights may be difficult to see in bright sunlight. If the front wheels won't spin fast enough to get monitor indication, start engine and slowly accelerate and decelerate front wheels. 5. If any monitor light fails to blink, check the suspected sensor, its air gap, wiring and connectors. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor: Service and Repair Front Fig. 108 Front Speed Sensor Replacement Refer to Fig. 108 when replacing front speed sensor. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 574 Wheel Speed Sensor: Service and Repair Rear Fig. 113 Rear Speed Sensor Replacement Refer to Fig. 113 when replacing rear speed sensor. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Photo 9 Coolant Temperature Sensor/Switch (For Computer): Locations Photo 9 Right Side Of Engine. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Photo 9 > Page 581 Coolant Temperature Sensor/Switch (For Computer): Locations Photo 14 Right Front Of Engine. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 582 Coolant Temperature Sensor/Switch (For Computer): Description and Operation PURPOSE/DESCRIPTION The engine coolant temperature sensor is a temperature dependant resistor (thermistor) that convents the engine coolant temperature to voltage and outputs it to the engine control module. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Locations Water Pump Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Locations > Page 586 Radiator Cooling Fan Temperature Sensor / Switch: Testing and Inspection 1. Drain cooling system and remove cooling fan temp switch from the thermostat housing. 2. Connect suitable ohmmeter between sensor terminals. 3. Heat thermo sensor in suitable solution while observing ohmmeter. 4. Meter should indicate continuity when temperature reaches 190-0.03degreesF. 5. Allow sensor to cool while observing meter. Meter should indicate no continuity as temperature drops below approximately 182-188degreesF. 6. If sensor fails to operate as outlined, sensor is defective. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Locations Temperature Sensor (Gauge): Locations Right Front Of Engine. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Lamp Switch (Cruise Control) <--> [Brake Switch (Cruise Control)] > Component Information > Locations Brake Lamp Switch (Cruise Control): Locations Behind Left Side Of Dash Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Lamp Switch (Cruise Control) <--> [Brake Switch (Cruise Control)] > Component Information > Locations > Page 594 Brake Lamp Switch (Cruise Control): Testing and Inspection 1. Disconnect 4-P connector from switch. Fig. 15 Brake Light Switch 2. Check for continuity between terminals, Fig. 15. 3. Adjust pedal height if necessary or replace switch if defective. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Testing and Inspection Clutch Switch: Testing and Inspection 1. Disconnect 2-P connector from switch. Fig. 17 Clutch Switch Components 2. Check for continuity between terminals, Fig. 17. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Testing and Inspection > Main Switch Test/Replacement Cruise Control Switch: Testing and Inspection Main Switch Test/Replacement 1. Carefully remove switch from instrument panel and disconnect electrical connectors. 2. Remove cruise control switch from switch panel. Fig. 29 Main Switch Test 3. Check for continuity between terminals in each switch position according to tables, Fig. 29. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Testing and Inspection > Main Switch Test/Replacement > Page 602 Cruise Control Switch: Testing and Inspection Set/Resume Switch Test/Replacement 1. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. 2. Disconnect battery ground cable, then the positive cable. 3. Ensure wheels are in straight ahead position, then remove lower instrument panel cover. Fig. 37 Test Harness "C" Installation. W/Air Bag 4. Disconnect cable reel harness 6-P connector from air bag harness, then connect test harness C only to cable reel harness, Fig. 37. Fig. 38 Set/Resume Switch Test. W/Air Bag 5. Check for continuity between terminals of test harness C in each switch position, Fig. 38. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Testing and Inspection > Main Switch Test/Replacement > Page 603 Fig. 39 Set/Resume Switch Cover Removal 6. Check for continuity between terminals of test harness C in each switch position, Fig. 39. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Testing and Inspection > Main Switch Test/Replacement > Page 604 Fig. 40 Set/resume Switch Steering Wheel Location Test. W/Air Bag 7. Check for continuity between terminals in each switch position, Fig. 40. 8. If there is no continuity in any position, replace set/resume switch. 9. If there is continuity in every switch position, replace cable reel. 10. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Testing and Inspection > Main Switch Test/Replacement > Page 605 Cruise Control Switch: Testing and Inspection Shift Lever Position Switch 1. Remove front console. Fig. 43 Shift Lever Position Test 2. Check for continuity between terminals in each switch position, Fig. 43. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Air Conditioning Switch > Component Information > Testing and Inspection Air Conditioning Switch: Testing and Inspection A/C Switch Test Check for continuity between the terminals according to the table below. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions Blower Motor Switch: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 614 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 615 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 616 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 617 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 618 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 619 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 620 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 621 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 622 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 623 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 624 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 625 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 626 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 627 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 628 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 629 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 630 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 631 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 632 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 633 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 634 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 635 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 636 Blower Motor Switch: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 637 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 638 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 639 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 640 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 641 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 642 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 643 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 644 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 645 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 646 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 647 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 648 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 649 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 650 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 651 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 652 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 653 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 654 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 655 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 656 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 657 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 658 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 659 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 660 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 661 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 662 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Page 663 Blower Motor Switch: Testing and Inspection Heater Fan Switch Test Check for continuity between the terminals according to the table below. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations Evaporator Temperature Sensor / Switch: Locations Behind Glove Box Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 667 Evaporator Temperature Sensor / Switch: Description and Operation The A/C thermostat is located on the evaporator housing. The A/C thermostat turns OFF the A/C compressor clutch if the temperature at the evaporator goes below 3°C (37°F). This prevents condensation from freezing on the evaporator fins and blocking the air delivery into the passenger compartment. If the temperature goes below 3°C (37°F) turning OFF the A/C thermostat, ground will be removed from the condenser fan relay. The relay will deenergize removing voltage from the condenser fan motor causing it to stop running. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 668 Evaporator Temperature Sensor / Switch: Testing and Inspection A/C Thermostat Test Connect battery power to terminal C and ground terminal B, and connect a test light between terminals A and C. NOTE: Use a 12 V, 3 W - 18 W test light. Dip the A/C thermostat into a cup filled with ice water, and check the test light. The light should go off at 37°F (3°C) or less, and should come on at 39°F (4°C) or more. If the light doesn't come on and go off as specified, replace the A/C thermostat. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations Refrigerant Pressure Sensor / Switch: Locations Photo 19 - A/C Pressure Switch Left Front Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 672 Refrigerant Pressure Sensor / Switch: Description and Operation Battery voltage is supplied through fuse 35 to the A/C compressor clutch relay contacts at all times. With the ignition switch in ON (II), voltage is applied to the coil of the A/C compressor clutch relay through fuse 13. When you push the A/C switch ON, and the heater fan switch is in position 1, 2, 3, or 4, a "ground" input is provided to the engine control module (ECM) through the A/C thermostat and the A/C pressure switch. The A/C compressor clutch relay is grounded by the engine control module (ECM). When energized, the A/C compressor clutch relay allows battery voltage to turn on the A/C compressor clutch. The A/C ON indicator light comes on when the A/C system is requested. The A/C pressure switch is located in the condenser outlet line where refrigerant is in a high temperature/high pressure liquid state. The switch will sense abnormally high or low pressure, and open the circuit. This removes ground, and the compressor will stop running. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Photo 90 Door Switch: Locations Photo 90 Rear Of Driver's Door Area (Right Front Similar) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Photo 90 > Page 678 Door Switch: Locations Rear Door Switch Rear Of Left Door Area (Right Similar) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Description and Operation Key Reminder Switch: Description and Operation Battery voltage is supplied at all times to the seat belt reminder/key-ON beeper circuit in the integrated control unit. When you turn ON the ignition key switch the integrated control unit senses ground. If you open the driver's door, the door switch closes, causing the beeper to sound until the door is closed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Parking Brake Switch Parking Brake Warning Switch: Locations Parking Brake Switch Below Rear Console Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Parking Brake Switch > Page 686 Parking Brake Warning Switch: Locations Parking Pin Switch Below Center Console Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations Backup Lamp Switch: Locations Right Front Of Engine Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Service and Repair Brake Light Switch: Service and Repair 1. Disconnect wiring at switch. 2. Loosen locknut and remove switch. 3. Reverse procedure to install. Allow 0.039-0.196 inch (1-5 mm) brake pedal freeplay. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Testing and Inspection Combination Switch: Testing and Inspection Combination Light Switch / Test Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Testing and Inspection > Page 697 CAUTION: All SRS wire harnesses are covered with yellow insulation. Before you disconnect any part of an SRS wire harness, connect the short connectors. Whenever the ignition switch is ON (II), or has been turned OFF for less than three minutes, be careful not to bump the SRS unit; the airbags could accidentally deploy and cause damage or injuries. 1. Remove the dashboard lower cover and steering column covers. 2. Disconnect the 4-P and 7-P connectors from the switch. 3. Check the connector terminals to be sure they are all making good contact. If the terminals are bent, loose, or corroded, repair them as necessary, and recheck the system. 4. Check for continuity between the terminals in each switch position according to the table. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Photo 90 Door Switch: Locations Photo 90 Rear Of Driver's Door Area (Right Front Similar) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Photo 90 > Page 702 Door Switch: Locations Rear Door Switch Rear Of Left Door Area (Right Similar) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions Headlamp Switch: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 707 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 708 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 709 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 710 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 711 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 712 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 713 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 714 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 715 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 716 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 717 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 718 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 719 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 720 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 721 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 722 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 723 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 724 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 725 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 726 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 727 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 728 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 729 Headlamp Switch: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 730 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 731 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 732 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 733 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 734 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 735 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 736 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 737 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 738 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 739 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 740 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 741 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 742 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 743 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 744 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 745 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 746 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 747 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 748 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 749 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 750 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 751 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 752 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 753 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 754 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 755 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 756 Headlamp Switch: Electrical Diagrams Headlight Switch (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 757 Headlight Switch (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 758 Headlight Switch (Part 3 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 759 Headlamp Switch: Service and Repair 1. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. 2. Disconnect battery ground cable. 3. Remove dashboard lower cover. 4. Remove steering column upper and lower covers. 5. Disconnect switch electrical connectors. 6. Remove two switch attaching screws, then slide switch assembly out of housing. 7. Reverse procedure to install. 8. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Testing and Inspection Horn Switch: Testing and Inspection CAUTION: All SRS wire harnesses are covered with yellow insulation. Before you disconnect any part of an SRS wire harness, connect the short connectors. Whenever the ignition switch ON (II), or has been turned OFF for less than three minutes, be careful not to bump the SRS unit, the airbags could accidentally deploy and cause damage or injuries. NOTE: The original radio has a coded theft protection circuit. Be sure to get the customer's code number before, - disconnecting the battery. - removing the No.32 (7.5 A) fuse from the under hood fuse/relay box. - removing the radio. After service, reconnect power to the radio and turn it on. When the word "CODE" is displayed, enter the customer's 5~digit code to restore radio operation. 1. Disconnect both the negative cable and positive cable from the banery, and wait at least three minutes. 2. Make sure the wheels are turned straight ahead. 3. Remove the access panel below the driver's airbag, then remove the short connector (RED) from the panel. 4. Disconnect the 3-P connector between the driver's 'airbag and cable reel, then connect the short connector (RED) on the airbag side of the connector. 5. Remove the glove box and access panel. 6. Disconnect the 3-P connector between the front passenger's airbag and the SRS main harness, then connect the short connector (RED) on the airbag side of the connector. 7. Remove the dashboard lower cover and knee bolster. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Testing and Inspection > Page 763 8. Disconnect the cable reel harness 6-P connector from the SRS main harness, then connect Test Harness C only to the cable reel harness. 9. Check for continuity between the No.3 terminal and body ground with the horn switch pressed. There should be continuity. 10. Remove the two TORX® bolts using a TORX® T30 bit, then remove the driver's airbag assembly. 11. Check for continuity between the horn switch positive terminal and the steering column shaft with the horn switch pressed. If there is continuity. - With cruise control: Test the set/resume switch. If the switch is OK, replace the cable reel. - Without cruise control: Replace the cable reel. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Testing and Inspection > Page 764 If there is no continuity; - Remove the steering wheel and the four screws, then remove the steering wheel cover. Replace the faulty horn switch. 12. Reinstall the steering wheel. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection Turn Signal Switch: Testing and Inspection Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Page 768 CAUTION: All SRS wire harnesses are covered with yellow insulation. Before you disconnect any part of an SRS wire harness, connect the short connectors. Whenever the ignition switch is ON (II), or has been turned OFF for less than three minutes, be careful not to bump the SRS unit; the airbags could accidentally deploy and cause damage or injuries. 1. Remove the dashboard lower cover and steering column covers. 2. Disconnect the 4-P and 7-P connectors from the switch. 3. Check the connector terminals to be sure they are all making good contact. If the terminals are bent, loose, or corroded, repair them as necessary, and recheck the system. 4. Check for continuity between the terminals in each switch position according to the table. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Page 769 Turn Signal Switch: Service and Repair 1. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. 2. Disconnect battery ground cable. 3. Remove dashboard lower cover. 4. Remove steering column upper and lower covers. 5. Disconnect switch electrical connectors. 6. Remove two switch attaching screws, then slide switch assembly out of housing. 7. Reverse procedure to install. 8. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 776 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 777 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 778 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 779 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 780 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 781 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 782 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 783 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 784 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 785 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 786 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 787 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 788 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 789 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 790 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 791 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 792 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 793 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 794 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 795 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 796 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 797 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 798 Air Flow Meter/Sensor: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 799 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 800 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 801 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 802 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 803 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 804 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 805 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 806 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 807 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 808 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 809 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 810 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 811 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 812 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 813 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 814 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 815 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 816 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 817 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 818 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 819 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 820 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 821 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 822 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 823 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 824 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Description and Operation Barometric Pressure Sensor: Description and Operation PURPOSE Converts barometric pressure to a voltage signal for the engine control module. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation Camshaft Position Sensor: Description and Operation PURPOSE/OPERATION The CKP Sensor determines timing for Fuel Injection and ignition of each Cylinder and also detects Engine speed. The TDC Sensor determines Ignition Timing at start-up (cranking) and when crank angle is abnormal. The CYP Sensor detects the position of No. 1 Cylinder for sequential fuel injection to each Cylinder. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Page 831 Camshaft Position Sensor: Testing and Inspection Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Page 832 The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 4: A problem in the Crankshaft Position (CKP) Sensor circuit. The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 8: A problem in the Top Dead Center (TDC) Sensor circuit. The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 9: A problem in the Cylinder Position (CYP) Sensor circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Photo 9 Coolant Temperature Sensor/Switch (For Computer): Locations Photo 9 Right Side Of Engine. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Photo 9 > Page 837 Coolant Temperature Sensor/Switch (For Computer): Locations Photo 14 Right Front Of Engine. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 838 Coolant Temperature Sensor/Switch (For Computer): Description and Operation PURPOSE/DESCRIPTION The engine coolant temperature sensor is a temperature dependant resistor (thermistor) that convents the engine coolant temperature to voltage and outputs it to the engine control module. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 843 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 844 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 845 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 846 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 847 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 848 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 849 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 850 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 851 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 852 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 853 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 854 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 855 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 856 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 857 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 858 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 859 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 860 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 861 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 862 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 863 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 864 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 865 Crankshaft Position Sensor: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 866 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 867 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 868 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 869 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 870 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 871 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 872 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 873 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 874 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 875 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 876 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 877 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 878 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 879 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 880 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 881 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 882 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 883 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 884 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 885 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 886 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 887 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 888 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 889 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 890 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 891 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 892 Crankshaft Position Sensor: Testing and Inspection Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 893 The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 4: A problem in the Crankshaft Position (CKP) Sensor circuit. The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 8: A problem in the Top Dead Center (TDC) Sensor circuit. The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 9: A problem in the Cylinder Position (CYP) Sensor circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Electric Load Sensor > Component Information > Description and Operation Electric Load Sensor: Description and Operation PURPOSE/OPERATION The Electrical Load Detector informs the engine control module of the high electrical draw conditions. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Manifold Pressure/Vacuum Sensor: Locations Middle Of Engine Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 900 Manifold Pressure/Vacuum Sensor: Diagrams For Connector Views refer to "Powertrain Management : Diagrams". Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 901 Manifold Pressure/Vacuum Sensor: Description and Operation PURPOSE The MAP Sensor converts Manifold Absolute Pressure (vacuum) into electrical signals and inputs the Engine Control Module (ECM). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Locations > Photo 4 Heated Oxygen Sensor: Locations Photo 4 Right Front Of Engine Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Locations > Photo 4 > Page 906 Heated Oxygen Sensor: Locations Photo 5 Right Front Of Engine Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions Heated Oxygen Sensor: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 909 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 910 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 911 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 912 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 913 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 914 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 915 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 916 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 917 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 918 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 919 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 920 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 921 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 922 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 923 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 924 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 925 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 926 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 927 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 928 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 929 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 930 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 931 Heated Oxygen Sensor: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 932 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 933 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 934 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 935 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 936 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 937 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 938 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 939 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 940 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 941 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 942 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 943 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 944 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 945 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 946 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 947 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 948 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 949 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 950 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 951 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 952 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 953 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 954 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 955 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 956 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 957 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Page 958 Heated Oxygen Sensor: Description and Operation The Oxygen Sensor is mounted to the Exhaust Manifold or pipe with the sensor end extending into the exhaust stream. It uses zirconia and platinum to compare exhaust oxygen content with that of the outside air. When heated by the combination of its internal heater and exhaust gases, the sensor supplies a low voltage signal (0.0 - 1.0 volt) to the ECM. When the engine is running rich, the oxygen differential is relatively high so signal voltage increases. When a lean condition occurs the difference in oxygen content is much lower causing a lower voltage signal to be produced. Oxygen sensor operation is monitored by the Engine Control Module (ECM) and a malfunction should be accompanied by a Diagnostic Trouble Code (DTC). Circuit and output testing procedures are covered in detail in the Diagnostic Trouble Code Charts. See: Powertrain Management/Computers and Control Systems/Testing and Inspection Oxygen Sensor malfunctions will cause increased emission output and smog check failure. Other symptoms may include poor idle quality or poor fuel economy. HINT: When monitoring oxygen sensor operation with an oscilloscope, watch for a sine wave with a frequency of at least 8 cycles in 10 seconds. A "lazy" oxygen sensor will not always set a code, but will usually cause abnormal emissions levels. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations Power Steering Pressure Switch: Locations Center Rear Of Engine Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 962 Power Steering Pressure Switch: Diagrams For Connector Views refer to "Powertrain Management : Diagrams". Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 963 Power Steering Pressure Switch: Description and Operation PURPOSE This signals the Engine Control Module (ECM) when the Power Steering load is high. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 964 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions Throttle Full Open Switch: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 969 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 970 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 971 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 972 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 973 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 974 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 975 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 976 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 977 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 978 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 979 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 980 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 981 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 982 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 983 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 984 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 985 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 986 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 987 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 988 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 989 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 990 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 991 Throttle Full Open Switch: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 992 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 993 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 994 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 995 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 996 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 997 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 998 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 999 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1000 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1001 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1002 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1003 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1004 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1005 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1006 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1007 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1008 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1009 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1010 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1011 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1012 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1013 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1014 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1015 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1016 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1017 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations Center Rear Of Engine Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 1021 Throttle Position Sensor: Diagrams For Connector Views refer to "Powertrain Management : Diagrams". Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 1022 Throttle Position Sensor: Description and Operation PURPOSE/OPERATION The TP Sensor is a Potentiometer. It is connected to the Throttle Valve Shaft. As the Throttle Position changes, the Throttle Position Sensor varies the voltage signal to the Engine Control Module (ECM). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > A/T Gear Position Signal <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Locations A/T Gear Position Signal: Locations Below Center Console Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > A/T Gear Position Signal <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Locations > Page 1026 A/T Gear Position Signal: Description and Operation PURPOSE This signals the Engine Control Module (ECM) when the Transmission is in Neutral or Park position. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > A/T Gear Position Signal <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Locations > Page 1027 A/T Gear Position Signal: Testing and Inspection Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > A/T Gear Position Signal <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Locations > Page 1028 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Variable Valve Timing Pressure Switch > Component Information > Diagrams Variable Valve Timing Pressure Switch: Diagrams For Connector Views refer to "Powertrain Management : Diagrams". Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Vehicle Speed Sensor: Locations Right Rear Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1037 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1038 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1039 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1040 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1041 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1042 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1043 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1044 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1045 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1046 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1047 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1048 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1049 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1050 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1051 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1052 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1053 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1054 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1055 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1056 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1057 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1058 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1059 Vehicle Speed Sensor: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1060 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1061 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1062 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1063 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1064 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1065 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1066 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1067 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1068 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1069 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1070 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1071 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1072 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1073 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1074 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1075 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1076 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1077 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1078 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1079 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1080 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1081 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1082 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1083 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1084 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1085 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1086 Vehicle Speed Sensor: Connector Views For Connector Views refer to "Powertrain Management : Diagrams". Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 1087 Vehicle Speed Sensor: Description and Operation With the ignition switch in ON (II) or START (III), battery voltage is supplied from fuse 24 (fuse 12 without SRS) through the BLK/YEL wire to the Vehicle Speed Sensor (VSS). The sensor is grounded by the BLK wire to G101. The speedometer and other control units in the circuit supply about 5 volts to the YEL/WHT wire. The vehicle speed sensor (VSS) intermittently grounds the YEL/WHT wire which generates a pulsed signal in it. The number of pulse per minute increases/decreases with the speed of the car. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 1088 Vehicle Speed Sensor: Testing and Inspection Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 1089 The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 17: A problem in the Vehicle Speed Sensor (VSS) circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1095 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1096 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1097 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1098 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1099 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1100 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1101 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1102 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1103 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1104 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1105 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1106 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1107 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1108 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1109 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1110 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1111 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1112 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1113 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1114 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1115 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1116 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1117 Air Flow Meter/Sensor: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1118 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1119 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1120 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1121 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1122 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1123 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1124 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1125 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1126 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1127 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1128 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1129 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1130 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1131 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1132 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1133 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1134 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1135 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1136 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1137 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1138 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1139 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1140 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1141 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1142 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1143 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions Throttle Full Open Switch: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1148 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1149 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1150 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1151 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1152 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1153 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1154 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1155 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1156 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1157 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1158 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1159 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1160 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1161 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1162 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1163 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1164 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1165 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1166 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1167 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1168 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1169 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1170 Throttle Full Open Switch: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1171 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1172 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1173 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1174 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1175 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1176 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1177 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1178 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1179 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1180 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1181 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1182 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1183 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1184 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1185 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1186 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1187 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1188 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1189 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1190 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1191 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1192 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1193 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1194 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1195 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1196 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations Center Rear Of Engine Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 1200 Throttle Position Sensor: Diagrams For Connector Views refer to "Powertrain Management : Diagrams". Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 1201 Throttle Position Sensor: Description and Operation PURPOSE/OPERATION The TP Sensor is a Potentiometer. It is connected to the Throttle Valve Shaft. As the Throttle Position changes, the Throttle Position Sensor varies the voltage signal to the Engine Control Module (ECM). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation Camshaft Position Sensor: Description and Operation PURPOSE/OPERATION The CKP Sensor determines timing for Fuel Injection and ignition of each Cylinder and also detects Engine speed. The TDC Sensor determines Ignition Timing at start-up (cranking) and when crank angle is abnormal. The CYP Sensor detects the position of No. 1 Cylinder for sequential fuel injection to each Cylinder. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Page 1206 Camshaft Position Sensor: Testing and Inspection Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Page 1207 The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 4: A problem in the Crankshaft Position (CKP) Sensor circuit. The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 8: A problem in the Top Dead Center (TDC) Sensor circuit. The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 9: A problem in the Cylinder Position (CYP) Sensor circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1212 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1213 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1214 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1215 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1216 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1217 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1218 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1219 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1220 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1221 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1222 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1223 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1224 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1225 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1226 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1227 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1228 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1229 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1230 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1231 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1232 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1233 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1234 Crankshaft Position Sensor: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1235 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1236 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1237 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1238 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1239 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1240 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1241 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1242 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1243 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1244 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1245 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1246 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1247 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1248 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1249 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1250 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1251 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1252 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1253 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1254 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1255 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1256 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1257 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1258 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1259 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1260 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 1261 Crankshaft Position Sensor: Testing and Inspection Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 1262 The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 4: A problem in the Crankshaft Position (CKP) Sensor circuit. The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 8: A problem in the Top Dead Center (TDC) Sensor circuit. The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 9: A problem in the Cylinder Position (CYP) Sensor circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch Ignition Switch Lock Cylinder: Technical Service Bulletins Starting System - Unable To Key In Ignition Switch Can't Turn Ignition Switch? Check for Locked Steering Got a service customer complaining he or she can't turn the ignition switch to start the engine? The reason could just be the steering column lock pin is engaged with the front wheels turned. Here's what typically happens: Some folks use the steering wheel to help support themselves while climbing in or out of the vehicle. This is very common among elderly or disabled drivers. Doing this turns the front wheels, which twists the tires against the ground. The twisted tires apply torque to the steering column. With the ignition switch in LOCK (0), the steering column lock pin is engaged. But the applied torque on the steering column binds the lock pin, making it tough to turn the ignition switch. The ignition switch won't turn to ON (II) if the lock pin isn't disengaged from the steering column. Tell your customer there's nothing wrong with the ignition switch itself. All he or she needs to do is turn the steering wheel from side to side while turning the switch. This usually releases the lock pin so the engine can be started. In some cases, though, your customer may need to give a good tug on the wheel. This could easily happen when parking on a hill and the wheels are turned sharply before the engine is shut off. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair Impact Sensor: Service and Repair 1. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. 2. Remove footrest and left door sill molding, then pull back carpet. Fig. 35 Dash Sensor Mounting 3. Remove dash sensor protector, then sensor mounting bolts and dash sensor, Fig. 35. 4. Reverse procedure to install, noting the following: a. Tighten dash attaching bolts to specifications. b. After completing installation, place ignition switch in On position. SRS indicator lamp should be illuminated for approximately six seconds, then lamp should turn off. If lamp remains illuminated or does not illuminate, a problem in the SRS is indicated. 5. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Safing Sensor, Air Bag > Component Information > Locations Safing Sensor: Locations The Safing Sensor is located within the SRS Unit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations Clutch Switch: Locations Behind Left Side Of Dash Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Testing and Inspection > Hitachi Starters Clutch Switch: Testing and Inspection Hitachi Starters 1. Remove instrument panel lower cover and left knee bolster. 2. Disconnect connector from switch. 3. With clutch pedal released, check continuity between both terminals. No continuity should be found. If continuity is found, replace or adjust switch as necessary. 4. With clutch pedal depressed, check continuity between both terminals. Continuity should be found. If no continuity is found, replace or adjust switch as necessary. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Testing and Inspection > Hitachi Starters > Page 1281 Clutch Switch: Testing and Inspection Mitsuba Starters 1. Remove instrument panel lower cover and left knee bolster. 2. Disconnect connector from switch. 3. With clutch pedal released, check continuity between both terminals. No continuity should be found. If continuity is found, replace or adjust switch as necessary. 4. With clutch pedal depressed, check continuity between both terminals. Continuity should be found. If no continuity is found, replace or adjust switch as necessary. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Testing and Inspection > Hitachi Starters > Page 1282 Clutch Switch: Testing and Inspection Nippondenso Starters 1. Remove instrument panel lower cover and left knee bolster. 2. Disconnect connector from switch. 3. With clutch pedal released, check continuity between both terminals. No continuity should be found. If continuity is found, replace or adjust switch as necessary. 4. With clutch pedal depressed, check continuity between both terminals. Continuity should be found. If no continuity is found, replace or adjust switch as necessary. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch Ignition Switch Lock Cylinder: Technical Service Bulletins Starting System - Unable To Key In Ignition Switch Can't Turn Ignition Switch? Check for Locked Steering Got a service customer complaining he or she can't turn the ignition switch to start the engine? The reason could just be the steering column lock pin is engaged with the front wheels turned. Here's what typically happens: Some folks use the steering wheel to help support themselves while climbing in or out of the vehicle. This is very common among elderly or disabled drivers. Doing this turns the front wheels, which twists the tires against the ground. The twisted tires apply torque to the steering column. With the ignition switch in LOCK (0), the steering column lock pin is engaged. But the applied torque on the steering column binds the lock pin, making it tough to turn the ignition switch. The ignition switch won't turn to ON (II) if the lock pin isn't disengaged from the steering column. Tell your customer there's nothing wrong with the ignition switch itself. All he or she needs to do is turn the steering wheel from side to side while turning the switch. This usually releases the lock pin so the engine can be started. In some cases, though, your customer may need to give a good tug on the wheel. This could easily happen when parking on a hill and the wheels are turned sharply before the engine is shut off. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations Power Steering Pressure Switch: Locations Center Rear Of Engine Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 1293 Power Steering Pressure Switch: Diagrams For Connector Views refer to "Powertrain Management : Diagrams". Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 1294 Power Steering Pressure Switch: Description and Operation PURPOSE This signals the Engine Control Module (ECM) when the Power Steering load is high. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 1295 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Locations Shift Interlock Switch: Locations Behind Left Side Of Dash Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > A/T Gear Position Signal <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Locations A/T Gear Position Signal: Locations Below Center Console Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > A/T Gear Position Signal <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Locations > Page 1304 A/T Gear Position Signal: Description and Operation PURPOSE This signals the Engine Control Module (ECM) when the Transmission is in Neutral or Park position. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > A/T Gear Position Signal <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Locations > Page 1305 A/T Gear Position Signal: Testing and Inspection Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > A/T Gear Position Signal <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Locations > Page 1306 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection Windshield Washer Switch: Testing and Inspection 1. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. 2. Remove steering column covers. 3. Disconnect 8-P and 6-P connectors from wiper switch. Fig. 9 Wiper/Washer Switch Continuity Chart 4. Check for continuity between terminals in each switch position according to table, Fig. 9. Replace switch as necessary. 5. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 1311 Windshield Washer Switch: Service and Repair 1. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. 2. Remove instrument panel lower cover. 3. Remove upper and lower steering column covers from steering column. 4. Disconnect 8-P and 6-P connectors from wiper switch. 5. Remove two attaching screws and slide wiper switch out of housing. 6. Reverse procedure to install. 7. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection Wiper Switch: Testing and Inspection 1. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. 2. Remove steering column covers. 3. Disconnect 8-P and 6-P connectors from wiper switch. Fig. 9 Wiper/Washer Switch Continuity Chart 4. Check for continuity between terminals in each switch position according to table, Fig. 9. Replace switch as necessary. 5. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 1315 Wiper Switch: Service and Repair 1. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. 2. Disconnect battery ground cable. 3. Remove dashboard lower cover. 4. Remove steering column upper cover. 5. Disconnect electrical connectors. 6. Remove wiper/washer switch attaching screws, then the switch. 7. Reverse procedure to install. 8. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right Alignment: Customer Interest Steering/Suspension - Vehicle Pulls Left/Right 06-068 May 2, 2009 Applies To: ALL *Vehicle Pulls or Drifts, and/or Steering Wheel Is Off-Center (Supersedes 06-068, Vehicle Pulling or Drifting, dated October 4, 2007, to revise the information marked by asterisks) (Replaces 90-011, Steering Wheel Off-Center Adjustment at PDI)* *REVISION SUMMARY The title description was revised.* SYMPTOM While driving on a straight road, the vehicle pulls or drifts to the right or left. BACKGROUND New tools were developed to help you diagnose and correct a pulling and/or steering wheel off-center issue. There is a diagnosis worksheet included to take on your test-drive and record your findings. These values are used to build the 15-digit DTC (diagnostic trouble code) that is required for your warranty claim. The last step in each repair procedure helps you create the correct code. In the rare case that you have to repair a vehicle that pulls and has the steering wheel off-center, use REPAIR PROCEDURE B to file your warranty claim. For more information, refer to Training Module SSC 44 - Steering Drift or Pull Interactive Service Bulletin. PROBABLE CAUSES Several conditions can cause the vehicle to pull or drift: ^ Wheel alignment ^ Tires ^ Off-center steering wheel (no pulling or drifting, but a customer may believe this is the case) CORRECTIVE ACTION Diagnose the problem using the special tools and the worksheet on page 4 that guides you to one of four repair procedures. TOOL INFORMATION Centering Tape (enough to diagnose 240 vehicles): T/N O7AAJ-001A300 Steering Drift Set Level: T/N 07AAJ-00100 Steering Drift Set: T/N O7MJ-001A140 Replacement Weight for Steering Drift Set: T/N 07AAJ-001A400 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 53560-SDA-AO1 H/C 7139652 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 1325 Defect Code: 07406 Symptom Code: 03602 Skill Level: Repair Technician Diagnostic Trouble Code: To create the 15-digit DTC, see the applicable repair procedure. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. TOOL DESCRIPTIONS The holding force gauge measures the amount of pull on the vehicle. It is a bracket that counts as one weight, plus five removable weights. During the test-drive, attach the bracket and the weights to the steering wheel on the side opposite the pulling direction. For example, if the vehicle pulls to the right, attach the bracket and weights to the left side of the steering wheel. Start with the maximum amount of weight on the steering wheel, and remove the weights until the vehicle drives in a straight line. When recording the pull on the worksheet, write down the direction of the pull (lefi or right) and the number of weights required to balance the pull (one through six). For example, if you have the bracket and two weights on the steering wheel, then record this as three weights. NOTE: The bracket counts as one weight. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 1326 The road crown gauge measures the amount of road crown. Almost all roads have a crown to help drain water during rainstorms. Use the suction cup to attach the road crown gauge bracket to the vehicle in a vertical position. If necessary, bend the bracket until the gauge is vertical. Once you attach and align the road crown gauge, calibrate the gauge to zero. There are two ways to calibrate the gauge: ^ Park the vehicle on a level surface, such as an alignment rack, and calibrate the gauge by moving the gauge until the ball is on the zero mark. ^ If you do not have a perfectly flat surface, park the vehicle on a reasonably flat surface and note the gauge reading. Turn the vehicle 1800 and, with the tires in the same spot, note the new gauge reading. Then move the gauge half of the difference. For example, if your first reading is +3 and, after moving the vehicle, the gauge reads -1, then the difference is 4 degrees. Position the gauge to read +1. NOTE: You must calibrate the gauge with the same weight in the vehicle that you will use for the test-drive. If you plan to have an assistant help you during the test-drive, calibrate the gauge while both of you are sitting in the vehicle. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 1327 The steering wheel offset gauge is a sticker that attaches to the steering wheel and the steering column cover. Place the sticker on the steering wheel when the steering wheel is straight. When you test-drive the vehicle, you can read how many millimeters the steering wheel is off-center. NOTE: If the vehicle is pulling, repairing the pull may correct the steering wheel offset. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 1328 DIAGNOSTIC WORKSHEET REPAIR PROCEDURE A Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 1329 NOTE: Do this repair procedure if, after doing step 10 of the test-drive, the vehicle pulled in the opposite direction after you swapped the front tires. 1. Swap wheels 2 and 4 on the passenger's side of the vehicle, and test-drive again. ^ If the pull goes away, replace the tire on wheel 2, then go to step 3. ^ If the pull does not go away, put wheels 2 and 4 back to their original positions, and go to step 2. 2. Swap wheels 1 and 3 on the driver's side of the vehicle, and test-drive again. ^ If the pull goes away, replace the tire on wheel 1, then go to step 3. ^ If the pull does not go away, use a known-good tire in position 1 and continue diagnosis. 3. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. REPAIR PROCEDURE B Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 1330 1. Place the vehicle on a commercially available, computerized, four-wheel alignment rack, and record the following measurements. Follow the equipment manufacturer's instructions. NOTE: Enter each reading in decimal degrees. Example 30' = 0.50. 2. If any measurement is out of specification, inspect the front suspension for any damage. Repair any damaged parts before continuing your diagnosis. 3. Determine how the front wheel camber is affecting the pull. Pick the combination of left- and right-front camber that best matches the vehicle you are repairing, then note the camber thrust direction for that combination: NOTE: ^ If the camber of both front wheels is negative, but one wheel is grossly more negative than the other, the camber thrust direction will be opposite the wheel with more negative camber (for example, if the left-front wheel is more negative, the camber thrust direction is right). ^ If the camber of both front wheels is positive, but one wheel is grossly more positive than the other, the camber thrust direction will be the same as the wheel with more positive camber (for example, if the left-front wheel is more positive, the camber thrust direction is left). 4. Determine how the camber needs to be adjusted. 5. Adjust the camber as needed. Front Camber Adjustment, Double Wishbone Suspension Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 1331 ^ Loosen the front subframe bolts. See the applicable service manual for more information. NOTE: The front wheels are being viewed from the rear of the vehicle. ^ Depending which way you need to shift the subframe, insert a pry bar between the subframe and body at both the front and rear positions of the subframe. NOTE: Be careful not to damage the vehicle. You could bend and damage the frame and/or body if you apply too much pressure. ^ Press on both pry bars to shift the subframe. It will move only a few millimeters. This should adjust the camber about 0.2-0.5°. ^ While holding the subframe in place, have an assistant torque the subframe bolts to their proper torque. Front Camber Adjustment, Strut Suspension ^ Raise the vehicle, and remove the front tires. ^ Loosen the damper pinch bolts and the flange nuts. ^ Adjust the camber by moving the bottom of the damper within the range of the damper pinch bolt free play. NOTE: Some vehicles have special pinch bolts that allow more adjustment. For more information, refer to the parts catalog. ^ Tighten the damper pinch bolts to the specified torque. ^ Reinstall the front wheels and lower the vehicle. Bounce the front of the vehicle several times to stabilize the suspension. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 1332 6. Test-drive the vehicle to make sure it no longer pulls. If the steering wheel is now off-center by more than 2 mm, go to REPAIR PROCEDURE C. 7. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. NOTE: Enter each reading in decimal degrees. Example 30' = 0.50. REPAIR PROCEDURE C 1. Make sure the steering wheel is centered. ^ Turn the steering wheel all the way to the right until it stops. ^ Turn the steering wheel all the way to the left, and count the number of revolutions until it stops. ^ Divide the number of revolutions in half, and turn the steering wheel until it is centered. For example, if it takes four revolutions of the steering wheel to go from lock to lock, then two turns is centered. ^ If the steering wheel is off-center by a large amount (20 mm or more), it may not be centered on the steering column shaft. Reinstall the steering wheel before going to step 2. 2. Place the vehicle on a lift, turn the steering wheel until it is centered, and then raise the vehicle. 3. Adjust the tie-rods. Use your measurements from question 13 of the test-drive to make your adjustment. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 1333 ^ If the wheels are pointed to the right, shorten the driver's side tie-rod, and lengthen the passenger's side. ^ If the wheels are pointed to the left, shorten the passenger's side tie-rod, and lengthen the driver's side. ^ Each 360° turn of the tie-rod equals about 8 mm of steering wheel adjustment. For example, a steering wheel is off-center by 4 mm with the front wheels pointed right (when the steering wheel is centered). To correct the off-center, shorten the driver's side tie-rod by a half-turn, and lengthen the passenger's side tie-rod by a half-turn. 4. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right Alignment: All Technical Service Bulletins Steering/Suspension - Vehicle Pulls Left/Right 06-068 May 2, 2009 Applies To: ALL *Vehicle Pulls or Drifts, and/or Steering Wheel Is Off-Center (Supersedes 06-068, Vehicle Pulling or Drifting, dated October 4, 2007, to revise the information marked by asterisks) (Replaces 90-011, Steering Wheel Off-Center Adjustment at PDI)* *REVISION SUMMARY The title description was revised.* SYMPTOM While driving on a straight road, the vehicle pulls or drifts to the right or left. BACKGROUND New tools were developed to help you diagnose and correct a pulling and/or steering wheel off-center issue. There is a diagnosis worksheet included to take on your test-drive and record your findings. These values are used to build the 15-digit DTC (diagnostic trouble code) that is required for your warranty claim. The last step in each repair procedure helps you create the correct code. In the rare case that you have to repair a vehicle that pulls and has the steering wheel off-center, use REPAIR PROCEDURE B to file your warranty claim. For more information, refer to Training Module SSC 44 - Steering Drift or Pull Interactive Service Bulletin. PROBABLE CAUSES Several conditions can cause the vehicle to pull or drift: ^ Wheel alignment ^ Tires ^ Off-center steering wheel (no pulling or drifting, but a customer may believe this is the case) CORRECTIVE ACTION Diagnose the problem using the special tools and the worksheet on page 4 that guides you to one of four repair procedures. TOOL INFORMATION Centering Tape (enough to diagnose 240 vehicles): T/N O7AAJ-001A300 Steering Drift Set Level: T/N 07AAJ-00100 Steering Drift Set: T/N O7MJ-001A140 Replacement Weight for Steering Drift Set: T/N 07AAJ-001A400 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 53560-SDA-AO1 H/C 7139652 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 1339 Defect Code: 07406 Symptom Code: 03602 Skill Level: Repair Technician Diagnostic Trouble Code: To create the 15-digit DTC, see the applicable repair procedure. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. TOOL DESCRIPTIONS The holding force gauge measures the amount of pull on the vehicle. It is a bracket that counts as one weight, plus five removable weights. During the test-drive, attach the bracket and the weights to the steering wheel on the side opposite the pulling direction. For example, if the vehicle pulls to the right, attach the bracket and weights to the left side of the steering wheel. Start with the maximum amount of weight on the steering wheel, and remove the weights until the vehicle drives in a straight line. When recording the pull on the worksheet, write down the direction of the pull (lefi or right) and the number of weights required to balance the pull (one through six). For example, if you have the bracket and two weights on the steering wheel, then record this as three weights. NOTE: The bracket counts as one weight. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 1340 The road crown gauge measures the amount of road crown. Almost all roads have a crown to help drain water during rainstorms. Use the suction cup to attach the road crown gauge bracket to the vehicle in a vertical position. If necessary, bend the bracket until the gauge is vertical. Once you attach and align the road crown gauge, calibrate the gauge to zero. There are two ways to calibrate the gauge: ^ Park the vehicle on a level surface, such as an alignment rack, and calibrate the gauge by moving the gauge until the ball is on the zero mark. ^ If you do not have a perfectly flat surface, park the vehicle on a reasonably flat surface and note the gauge reading. Turn the vehicle 1800 and, with the tires in the same spot, note the new gauge reading. Then move the gauge half of the difference. For example, if your first reading is +3 and, after moving the vehicle, the gauge reads -1, then the difference is 4 degrees. Position the gauge to read +1. NOTE: You must calibrate the gauge with the same weight in the vehicle that you will use for the test-drive. If you plan to have an assistant help you during the test-drive, calibrate the gauge while both of you are sitting in the vehicle. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 1341 The steering wheel offset gauge is a sticker that attaches to the steering wheel and the steering column cover. Place the sticker on the steering wheel when the steering wheel is straight. When you test-drive the vehicle, you can read how many millimeters the steering wheel is off-center. NOTE: If the vehicle is pulling, repairing the pull may correct the steering wheel offset. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 1342 DIAGNOSTIC WORKSHEET REPAIR PROCEDURE A Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 1343 NOTE: Do this repair procedure if, after doing step 10 of the test-drive, the vehicle pulled in the opposite direction after you swapped the front tires. 1. Swap wheels 2 and 4 on the passenger's side of the vehicle, and test-drive again. ^ If the pull goes away, replace the tire on wheel 2, then go to step 3. ^ If the pull does not go away, put wheels 2 and 4 back to their original positions, and go to step 2. 2. Swap wheels 1 and 3 on the driver's side of the vehicle, and test-drive again. ^ If the pull goes away, replace the tire on wheel 1, then go to step 3. ^ If the pull does not go away, use a known-good tire in position 1 and continue diagnosis. 3. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. REPAIR PROCEDURE B Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 1344 1. Place the vehicle on a commercially available, computerized, four-wheel alignment rack, and record the following measurements. Follow the equipment manufacturer's instructions. NOTE: Enter each reading in decimal degrees. Example 30' = 0.50. 2. If any measurement is out of specification, inspect the front suspension for any damage. Repair any damaged parts before continuing your diagnosis. 3. Determine how the front wheel camber is affecting the pull. Pick the combination of left- and right-front camber that best matches the vehicle you are repairing, then note the camber thrust direction for that combination: NOTE: ^ If the camber of both front wheels is negative, but one wheel is grossly more negative than the other, the camber thrust direction will be opposite the wheel with more negative camber (for example, if the left-front wheel is more negative, the camber thrust direction is right). ^ If the camber of both front wheels is positive, but one wheel is grossly more positive than the other, the camber thrust direction will be the same as the wheel with more positive camber (for example, if the left-front wheel is more positive, the camber thrust direction is left). 4. Determine how the camber needs to be adjusted. 5. Adjust the camber as needed. Front Camber Adjustment, Double Wishbone Suspension Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 1345 ^ Loosen the front subframe bolts. See the applicable service manual for more information. NOTE: The front wheels are being viewed from the rear of the vehicle. ^ Depending which way you need to shift the subframe, insert a pry bar between the subframe and body at both the front and rear positions of the subframe. NOTE: Be careful not to damage the vehicle. You could bend and damage the frame and/or body if you apply too much pressure. ^ Press on both pry bars to shift the subframe. It will move only a few millimeters. This should adjust the camber about 0.2-0.5°. ^ While holding the subframe in place, have an assistant torque the subframe bolts to their proper torque. Front Camber Adjustment, Strut Suspension ^ Raise the vehicle, and remove the front tires. ^ Loosen the damper pinch bolts and the flange nuts. ^ Adjust the camber by moving the bottom of the damper within the range of the damper pinch bolt free play. NOTE: Some vehicles have special pinch bolts that allow more adjustment. For more information, refer to the parts catalog. ^ Tighten the damper pinch bolts to the specified torque. ^ Reinstall the front wheels and lower the vehicle. Bounce the front of the vehicle several times to stabilize the suspension. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 1346 6. Test-drive the vehicle to make sure it no longer pulls. If the steering wheel is now off-center by more than 2 mm, go to REPAIR PROCEDURE C. 7. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. NOTE: Enter each reading in decimal degrees. Example 30' = 0.50. REPAIR PROCEDURE C 1. Make sure the steering wheel is centered. ^ Turn the steering wheel all the way to the right until it stops. ^ Turn the steering wheel all the way to the left, and count the number of revolutions until it stops. ^ Divide the number of revolutions in half, and turn the steering wheel until it is centered. For example, if it takes four revolutions of the steering wheel to go from lock to lock, then two turns is centered. ^ If the steering wheel is off-center by a large amount (20 mm or more), it may not be centered on the steering column shaft. Reinstall the steering wheel before going to step 2. 2. Place the vehicle on a lift, turn the steering wheel until it is centered, and then raise the vehicle. 3. Adjust the tie-rods. Use your measurements from question 13 of the test-drive to make your adjustment. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 1347 ^ If the wheels are pointed to the right, shorten the driver's side tie-rod, and lengthen the passenger's side. ^ If the wheels are pointed to the left, shorten the passenger's side tie-rod, and lengthen the driver's side. ^ Each 360° turn of the tie-rod equals about 8 mm of steering wheel adjustment. For example, a steering wheel is off-center by 4 mm with the front wheels pointed right (when the steering wheel is centered). To correct the off-center, shorten the driver's side tie-rod by a half-turn, and lengthen the passenger's side tie-rod by a half-turn. 4. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 1348 Alignment: By Symptom Technical Service Bulletin # 06-068 Date: 090502 Steering/Suspension - Vehicle Pulls Left/Right 06-068 May 2, 2009 Applies To: ALL *Vehicle Pulls or Drifts, and/or Steering Wheel Is Off-Center (Supersedes 06-068, Vehicle Pulling or Drifting, dated October 4, 2007, to revise the information marked by asterisks) (Replaces 90-011, Steering Wheel Off-Center Adjustment at PDI)* *REVISION SUMMARY The title description was revised.* SYMPTOM While driving on a straight road, the vehicle pulls or drifts to the right or left. BACKGROUND New tools were developed to help you diagnose and correct a pulling and/or steering wheel off-center issue. There is a diagnosis worksheet included to take on your test-drive and record your findings. These values are used to build the 15-digit DTC (diagnostic trouble code) that is required for your warranty claim. The last step in each repair procedure helps you create the correct code. In the rare case that you have to repair a vehicle that pulls and has the steering wheel off-center, use REPAIR PROCEDURE B to file your warranty claim. For more information, refer to Training Module SSC 44 - Steering Drift or Pull Interactive Service Bulletin. PROBABLE CAUSES Several conditions can cause the vehicle to pull or drift: ^ Wheel alignment ^ Tires ^ Off-center steering wheel (no pulling or drifting, but a customer may believe this is the case) CORRECTIVE ACTION Diagnose the problem using the special tools and the worksheet on page 4 that guides you to one of four repair procedures. TOOL INFORMATION Centering Tape (enough to diagnose 240 vehicles): T/N O7AAJ-001A300 Steering Drift Set Level: T/N 07AAJ-00100 Steering Drift Set: T/N O7MJ-001A140 Replacement Weight for Steering Drift Set: T/N 07AAJ-001A400 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 1349 Failed Part: P/N 53560-SDA-AO1 H/C 7139652 Defect Code: 07406 Symptom Code: 03602 Skill Level: Repair Technician Diagnostic Trouble Code: To create the 15-digit DTC, see the applicable repair procedure. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. TOOL DESCRIPTIONS The holding force gauge measures the amount of pull on the vehicle. It is a bracket that counts as one weight, plus five removable weights. During the test-drive, attach the bracket and the weights to the steering wheel on the side opposite the pulling direction. For example, if the vehicle pulls to the right, attach the bracket and weights to the left side of the steering wheel. Start with the maximum amount of weight on the steering wheel, and remove the weights until the vehicle drives in a straight line. When recording the pull on the worksheet, write down the direction of the pull (lefi or right) and the number of weights required to balance the pull (one through six). For example, if you have the bracket and two weights on the steering wheel, then record this as three weights. NOTE: The bracket counts as one weight. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 1350 The road crown gauge measures the amount of road crown. Almost all roads have a crown to help drain water during rainstorms. Use the suction cup to attach the road crown gauge bracket to the vehicle in a vertical position. If necessary, bend the bracket until the gauge is vertical. Once you attach and align the road crown gauge, calibrate the gauge to zero. There are two ways to calibrate the gauge: ^ Park the vehicle on a level surface, such as an alignment rack, and calibrate the gauge by moving the gauge until the ball is on the zero mark. ^ If you do not have a perfectly flat surface, park the vehicle on a reasonably flat surface and note the gauge reading. Turn the vehicle 1800 and, with the tires in the same spot, note the new gauge reading. Then move the gauge half of the difference. For example, if your first reading is +3 and, after moving the vehicle, the gauge reads -1, then the difference is 4 degrees. Position the gauge to read +1. NOTE: You must calibrate the gauge with the same weight in the vehicle that you will use for the test-drive. If you plan to have an assistant help you during the test-drive, calibrate the gauge while both of you are sitting in the vehicle. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 1351 The steering wheel offset gauge is a sticker that attaches to the steering wheel and the steering column cover. Place the sticker on the steering wheel when the steering wheel is straight. When you test-drive the vehicle, you can read how many millimeters the steering wheel is off-center. NOTE: If the vehicle is pulling, repairing the pull may correct the steering wheel offset. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 1352 DIAGNOSTIC WORKSHEET REPAIR PROCEDURE A Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 1353 NOTE: Do this repair procedure if, after doing step 10 of the test-drive, the vehicle pulled in the opposite direction after you swapped the front tires. 1. Swap wheels 2 and 4 on the passenger's side of the vehicle, and test-drive again. ^ If the pull goes away, replace the tire on wheel 2, then go to step 3. ^ If the pull does not go away, put wheels 2 and 4 back to their original positions, and go to step 2. 2. Swap wheels 1 and 3 on the driver's side of the vehicle, and test-drive again. ^ If the pull goes away, replace the tire on wheel 1, then go to step 3. ^ If the pull does not go away, use a known-good tire in position 1 and continue diagnosis. 3. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. REPAIR PROCEDURE B Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 1354 1. Place the vehicle on a commercially available, computerized, four-wheel alignment rack, and record the following measurements. Follow the equipment manufacturer's instructions. NOTE: Enter each reading in decimal degrees. Example 30' = 0.50. 2. If any measurement is out of specification, inspect the front suspension for any damage. Repair any damaged parts before continuing your diagnosis. 3. Determine how the front wheel camber is affecting the pull. Pick the combination of left- and right-front camber that best matches the vehicle you are repairing, then note the camber thrust direction for that combination: NOTE: ^ If the camber of both front wheels is negative, but one wheel is grossly more negative than the other, the camber thrust direction will be opposite the wheel with more negative camber (for example, if the left-front wheel is more negative, the camber thrust direction is right). ^ If the camber of both front wheels is positive, but one wheel is grossly more positive than the other, the camber thrust direction will be the same as the wheel with more positive camber (for example, if the left-front wheel is more positive, the camber thrust direction is left). 4. Determine how the camber needs to be adjusted. 5. Adjust the camber as needed. Front Camber Adjustment, Double Wishbone Suspension Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 1355 ^ Loosen the front subframe bolts. See the applicable service manual for more information. NOTE: The front wheels are being viewed from the rear of the vehicle. ^ Depending which way you need to shift the subframe, insert a pry bar between the subframe and body at both the front and rear positions of the subframe. NOTE: Be careful not to damage the vehicle. You could bend and damage the frame and/or body if you apply too much pressure. ^ Press on both pry bars to shift the subframe. It will move only a few millimeters. This should adjust the camber about 0.2-0.5°. ^ While holding the subframe in place, have an assistant torque the subframe bolts to their proper torque. Front Camber Adjustment, Strut Suspension ^ Raise the vehicle, and remove the front tires. ^ Loosen the damper pinch bolts and the flange nuts. ^ Adjust the camber by moving the bottom of the damper within the range of the damper pinch bolt free play. NOTE: Some vehicles have special pinch bolts that allow more adjustment. For more information, refer to the parts catalog. ^ Tighten the damper pinch bolts to the specified torque. ^ Reinstall the front wheels and lower the vehicle. Bounce the front of the vehicle several times to stabilize the suspension. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 1356 6. Test-drive the vehicle to make sure it no longer pulls. If the steering wheel is now off-center by more than 2 mm, go to REPAIR PROCEDURE C. 7. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. NOTE: Enter each reading in decimal degrees. Example 30' = 0.50. REPAIR PROCEDURE C 1. Make sure the steering wheel is centered. ^ Turn the steering wheel all the way to the right until it stops. ^ Turn the steering wheel all the way to the left, and count the number of revolutions until it stops. ^ Divide the number of revolutions in half, and turn the steering wheel until it is centered. For example, if it takes four revolutions of the steering wheel to go from lock to lock, then two turns is centered. ^ If the steering wheel is off-center by a large amount (20 mm or more), it may not be centered on the steering column shaft. Reinstall the steering wheel before going to step 2. 2. Place the vehicle on a lift, turn the steering wheel until it is centered, and then raise the vehicle. 3. Adjust the tie-rods. Use your measurements from question 13 of the test-drive to make your adjustment. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 1357 ^ If the wheels are pointed to the right, shorten the driver's side tie-rod, and lengthen the passenger's side. ^ If the wheels are pointed to the left, shorten the passenger's side tie-rod, and lengthen the driver's side. ^ Each 360° turn of the tie-rod equals about 8 mm of steering wheel adjustment. For example, a steering wheel is off-center by 4 mm with the front wheels pointed right (when the steering wheel is centered). To correct the off-center, shorten the driver's side tie-rod by a half-turn, and lengthen the passenger's side tie-rod by a half-turn. 4. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. Technical Service Bulletin # 06-068 Date: 090502 Steering/Suspension - Vehicle Pulls Left/Right 06-068 May 2, 2009 Applies To: ALL *Vehicle Pulls or Drifts, and/or Steering Wheel Is Off-Center (Supersedes 06-068, Vehicle Pulling or Drifting, dated October 4, 2007, to revise the information marked by asterisks) (Replaces 90-011, Steering Wheel Off-Center Adjustment at PDI)* *REVISION SUMMARY The title description was revised.* SYMPTOM While driving on a straight road, the vehicle pulls or drifts to the right or left. BACKGROUND New tools were developed to help you diagnose and correct a pulling and/or steering wheel off-center issue. There is a diagnosis worksheet included to take on your test-drive and record your findings. These values are used to build the 15-digit DTC (diagnostic trouble code) that is required for your warranty claim. The last step in each repair procedure helps you create the correct code. In the rare case that you have to repair a vehicle that pulls and has the steering wheel off-center, use REPAIR PROCEDURE B to file your warranty claim. For more information, refer to Training Module SSC 44 - Steering Drift or Pull Interactive Service Bulletin. PROBABLE CAUSES Several conditions can cause the vehicle to pull or drift: ^ Wheel alignment ^ Tires ^ Off-center steering wheel (no pulling or drifting, but a customer may believe this is the case) CORRECTIVE ACTION Diagnose the problem using the special tools and the worksheet on page 4 that guides you to one of four repair procedures. TOOL INFORMATION Centering Tape (enough to diagnose 240 vehicles): T/N O7AAJ-001A300 Steering Drift Set Level: T/N 07AAJ-00100 Steering Drift Set: T/N O7MJ-001A140 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 1358 Replacement Weight for Steering Drift Set: T/N 07AAJ-001A400 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 53560-SDA-AO1 H/C 7139652 Defect Code: 07406 Symptom Code: 03602 Skill Level: Repair Technician Diagnostic Trouble Code: To create the 15-digit DTC, see the applicable repair procedure. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. TOOL DESCRIPTIONS The holding force gauge measures the amount of pull on the vehicle. It is a bracket that counts as one weight, plus five removable weights. During the test-drive, attach the bracket and the weights to the steering wheel on the side opposite the pulling direction. For example, if the vehicle pulls Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 1359 to the right, attach the bracket and weights to the left side of the steering wheel. Start with the maximum amount of weight on the steering wheel, and remove the weights until the vehicle drives in a straight line. When recording the pull on the worksheet, write down the direction of the pull (lefi or right) and the number of weights required to balance the pull (one through six). For example, if you have the bracket and two weights on the steering wheel, then record this as three weights. NOTE: The bracket counts as one weight. The road crown gauge measures the amount of road crown. Almost all roads have a crown to help drain water during rainstorms. Use the suction cup to attach the road crown gauge bracket to the vehicle in a vertical position. If necessary, bend the bracket until the gauge is vertical. Once you attach and align the road crown gauge, calibrate the gauge to zero. There are two ways to calibrate the gauge: ^ Park the vehicle on a level surface, such as an alignment rack, and calibrate the gauge by moving the gauge until the ball is on the zero mark. ^ If you do not have a perfectly flat surface, park the vehicle on a reasonably flat surface and note the gauge reading. Turn the vehicle 1800 and, with the tires in the same spot, note the new gauge reading. Then move the gauge half of the difference. For example, if your first reading is +3 and, after moving the vehicle, the gauge reads -1, then the difference is 4 degrees. Position the gauge to read +1. NOTE: You must calibrate the gauge with the same weight in the vehicle that you will use for the test-drive. If you plan to have an assistant help you during the test-drive, calibrate the gauge while both of you are sitting in the vehicle. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 1360 The steering wheel offset gauge is a sticker that attaches to the steering wheel and the steering column cover. Place the sticker on the steering wheel when the steering wheel is straight. When you test-drive the vehicle, you can read how many millimeters the steering wheel is off-center. NOTE: If the vehicle is pulling, repairing the pull may correct the steering wheel offset. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 1361 DIAGNOSTIC WORKSHEET REPAIR PROCEDURE A Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 1362 NOTE: Do this repair procedure if, after doing step 10 of the test-drive, the vehicle pulled in the opposite direction after you swapped the front tires. 1. Swap wheels 2 and 4 on the passenger's side of the vehicle, and test-drive again. ^ If the pull goes away, replace the tire on wheel 2, then go to step 3. ^ If the pull does not go away, put wheels 2 and 4 back to their original positions, and go to step 2. 2. Swap wheels 1 and 3 on the driver's side of the vehicle, and test-drive again. ^ If the pull goes away, replace the tire on wheel 1, then go to step 3. ^ If the pull does not go away, use a known-good tire in position 1 and continue diagnosis. 3. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. REPAIR PROCEDURE B Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 1363 1. Place the vehicle on a commercially available, computerized, four-wheel alignment rack, and record the following measurements. Follow the equipment manufacturer's instructions. NOTE: Enter each reading in decimal degrees. Example 30' = 0.50. 2. If any measurement is out of specification, inspect the front suspension for any damage. Repair any damaged parts before continuing your diagnosis. 3. Determine how the front wheel camber is affecting the pull. Pick the combination of left- and right-front camber that best matches the vehicle you are repairing, then note the camber thrust direction for that combination: NOTE: ^ If the camber of both front wheels is negative, but one wheel is grossly more negative than the other, the camber thrust direction will be opposite the wheel with more negative camber (for example, if the left-front wheel is more negative, the camber thrust direction is right). ^ If the camber of both front wheels is positive, but one wheel is grossly more positive than the other, the camber thrust direction will be the same as the wheel with more positive camber (for example, if the left-front wheel is more positive, the camber thrust direction is left). 4. Determine how the camber needs to be adjusted. 5. Adjust the camber as needed. Front Camber Adjustment, Double Wishbone Suspension Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 1364 ^ Loosen the front subframe bolts. See the applicable service manual for more information. NOTE: The front wheels are being viewed from the rear of the vehicle. ^ Depending which way you need to shift the subframe, insert a pry bar between the subframe and body at both the front and rear positions of the subframe. NOTE: Be careful not to damage the vehicle. You could bend and damage the frame and/or body if you apply too much pressure. ^ Press on both pry bars to shift the subframe. It will move only a few millimeters. This should adjust the camber about 0.2-0.5°. ^ While holding the subframe in place, have an assistant torque the subframe bolts to their proper torque. Front Camber Adjustment, Strut Suspension ^ Raise the vehicle, and remove the front tires. ^ Loosen the damper pinch bolts and the flange nuts. ^ Adjust the camber by moving the bottom of the damper within the range of the damper pinch bolt free play. NOTE: Some vehicles have special pinch bolts that allow more adjustment. For more information, refer to the parts catalog. ^ Tighten the damper pinch bolts to the specified torque. ^ Reinstall the front wheels and lower the vehicle. Bounce the front of the vehicle several times to stabilize the suspension. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 1365 6. Test-drive the vehicle to make sure it no longer pulls. If the steering wheel is now off-center by more than 2 mm, go to REPAIR PROCEDURE C. 7. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. NOTE: Enter each reading in decimal degrees. Example 30' = 0.50. REPAIR PROCEDURE C 1. Make sure the steering wheel is centered. ^ Turn the steering wheel all the way to the right until it stops. ^ Turn the steering wheel all the way to the left, and count the number of revolutions until it stops. ^ Divide the number of revolutions in half, and turn the steering wheel until it is centered. For example, if it takes four revolutions of the steering wheel to go from lock to lock, then two turns is centered. ^ If the steering wheel is off-center by a large amount (20 mm or more), it may not be centered on the steering column shaft. Reinstall the steering wheel before going to step 2. 2. Place the vehicle on a lift, turn the steering wheel until it is centered, and then raise the vehicle. 3. Adjust the tie-rods. Use your measurements from question 13 of the test-drive to make your adjustment. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 1366 ^ If the wheels are pointed to the right, shorten the driver's side tie-rod, and lengthen the passenger's side. ^ If the wheels are pointed to the left, shorten the passenger's side tie-rod, and lengthen the driver's side. ^ Each 360° turn of the tie-rod equals about 8 mm of steering wheel adjustment. For example, a steering wheel is off-center by 4 mm with the front wheels pointed right (when the steering wheel is centered). To correct the off-center, shorten the driver's side tie-rod by a half-turn, and lengthen the passenger's side tie-rod by a half-turn. 4. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Front Wheel Alignment Alignment: Specifications Front Wheel Alignment Caster Angle, Degrees Limits ................................................................................................................................................... ................................................ + 1/6 to +2 1/6 Desired ....................................................................... ........................................................................................................................................ +1 1/6 Camber Angle, Degrees Limits ................................................................................................................................................... ............................................................. -1 to +1 Desired ..................................................................... .................................................................................................................................................. 0 Toe-In, Inch ......................................................................................................................................... ................................................................................. 0 Wheel Turning Angle, Degrees Inner Wheel ......................................................................................................................................... ..................................................................... 41 Outer Wheel ............................................................. .......................................................................................................................................... 33 1/2 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Front Wheel Alignment > Page 1369 Alignment: Specifications Rear Wheel Alignment Camber Angle, Degrees Limits ................................................................................................................................................... .................................................. -1 1/3 to + 2/3 Desired ...................................................................... .............................................................................................................................................. -1/3 Toe-In, Inch ......................................................................................................................................... ............................................................................ 0.08 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1370 Alignment: Service Precautions CAUTION: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The correct torque value must be used when installing fasteners that require it. If the above conditions are not followed, parts or system damage could result. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > General Description Alignment: Description and Operation General Description GENERAL DESCRIPTION "Front End Alignment" refers to the angular relationship between the front wheels, the front suspension attaching parts and the ground. Proper front end alignment must be maintained in order to insure efficient steering, good directional stability and to prevent abnormal tire wear. The most important factors of front end alignment are wheel toe-in, wheel camber and axle caster. CAMBER: Camber is the vertical tilting inward or outward of the front wheels. When the wheels tilt outward at the top, the camber is positive (+). When the wheels tilt inward at the top, the camber is negative (-). The amount of tilt measured in degrees from the vertical is called the camber angle (1). If camber is extreme or unequal between the wheels, improper steering and excessive tire wear will result. Negative camber causes wear on the inside of the tire, while positive camber causes wear to the outside. CASTER: This illustration shows view from the side of the vehicle. Caster (1) is the vertical tilting of the wheel axis either forward or backward (when viewed from the side of the vehicle). A backward tilt is positive (+) and a forward tilt is negative (-). On the short and long arm type suspension you cannot see a caster angle without a special instrument, but if you look straight down from the top of the upper control arm to the ground, the ball joints do not line up (fore and aft) when a caster angle other than 0 degree is present. With a positive angle, the lower ball joint would be slightly ahead (toward the front of the vehicle) of the upper ball joint center line. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > General Description > Page 1373 TOE-IN: This illustration shows view from the top of the vehicle. Toe-in is the measured amount the front wheels are turn in. The actual amount of toe-in is normally a fraction of a degree. Toe-in is measured from the center of the tire treads or from the inside of the tires. The purpose of toe-in is to insure parallel rolling of the front wheels and to offset any small deflections of the wheel support system which occurs when the vehicle is rolling forward. Incorrect toe-in results in excessive toe-in and unstable steering. Toe-in is the last alignment to be set in the front end alignment procedure. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > General Description > Page 1374 Alignment: Description and Operation Camber Camber is the inward or outward tilting of the front wheels from the vertical. When the wheels tilt outward at the top, the camber is positive (+). When the wheels tilt inward at the top, the camber is negative (-). The amount of tilt measured in degrees from the vertical is called the camber angle. If camber is extreme or unequal between the wheels, improper steering and excessive tire wear will result. Negative camber causes wear on the inside of the tire, while positive camber causes wear to the outside. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > General Description > Page 1375 Alignment: Description and Operation Caster Caster is the tilting of the wheel axis either forward or backward from the vertical (when viewed from the side of the vehicle). A backward tilt is positive (+) and a forward tilt is negative (-). On the short and long arm type suspension you cannot see a caster angle without a special instrument, but if you look straight down from the top of the upper control arm to the ground, the ball joints do not line up (fore and aft) when a caster angle other than 0 degree is present. With a positive angle, the lower ball joint would be slightly ahead (toward the front of the vehicle) of the upper ball joint center line. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > General Description > Page 1376 Alignment: Description and Operation Toe-In Toe-in is the turning of the front wheels. The actual amount of toe-in is normally a fraction of a degree. Toe-in is measured from the center of the tire treads or from the inside of the tires. The purpose of toe-in is to insure parallel rolling of the front wheels and to offset any small deflections of the wheel support system which occurs when the vehicle is rolling forward. Incorrect toe-in results in excessive toe-in and unstable steering. Toe-in is the last alignment to be set in the front end alignment procedure. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Page 1377 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Preliminary Checks Alignment: Service and Repair Preliminary Checks INSPECTION Before making any adjustments affecting caster, camber or toe-in, the following front end inspection should be made. 1. Inspect the tires for proper inflation pressure. 2. Inspect the front wheel bearings for proper adjustment. 3. inspect the ball joints and tie rod ends. If excessive looseness is noted, correct before adjusting. 4. Inspect the wheel and tires for run-out. 5. Inspect the trim height. If not within specifications, the correction must be made before adjusting caster. 6. Inspect the steering unit for looseness at the frame. 7. Inspect shock absorbers for leaks or any noticeable noise. 8. Inspect the control arms or stabilizer bar attachment for looseness. 9. Inspect the front end alignment using alignment equipment. Follow the manufacturer's instructions. 10. Alignment must be performed on a level surface. - Check that the suspension is not modified. - Check the tire size and tire pressure. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Preliminary Checks > Page 1380 Alignment: Service and Repair Alignment Camber Ensure tires are properly inflated prior to checking or adjusting camber angles. Camber angles are not adjustable, however, the following procedure may be used to ensure camber is within specifications. Fig. 1 Camber Angle Inspection 1. Remove spindle nut and install suitable camber gauge and adapter, Fig. 1, with wheels in straight-ahead position. 2. Note gauge reading with bubble centered on the gauge. If camber is not within specifications, inspect suspension components for damage and repair as necessary, then recheck camber. Caster Ensure tires are properly inflated prior to checking or adjusting caster angles. 1. Check steering wheel angle. If significantly off center, it may be necessary to remove steering wheel and reposition it on splines. Turn steering wheel to straight ahead position. 2. Check caster angle. 3. If caster angle is not within specifications, inspect suspension components for damage and repair as necessary, then recheck caster. Toe-In Ensure tires are properly inflated prior to checking or adjusting toe-in. 1. Center steering wheel, then loosen tie rod locknuts. 2. Turn both tie rods in the same direction until both front wheels are positioned straight ahead. 3. Adjust toe to specifications by turning both tie rods in the same direction, then tighten tie rod locknuts. Camber Ensure tires are properly inflated prior to checking or adjusting camber angles. Camber angles are not adjustable, however, the following procedure may be used to ensure camber is within specifications. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Preliminary Checks > Page 1381 Fig. 1 Camber Angle Inspection 1. Remove spindle nut and install suitable camber gauge and adapter, Fig. 1, with wheels in straight-ahead position. 2. Note gauge reading with bubble centered on the gauge. If camber is not within specifications, inspect suspension components for damage and repair as necessary, then recheck camber. Toe-In 1. Release parking brake. 2. Before adjustment, note location of compensator arm adjusting bolts. Fig. 4 Rear Toe-In Adjustment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Preliminary Checks > Page 1382 3. Loosen adjusting bolt and slide compensator arm in or out, Fig. 4, to adjust toe. 4. Torque adjusting bolt to 47 ft. lbs. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > Tools - New Fuel Pressure Gauge and Replacement Parts Fuel Pressure: Technical Service Bulletins Tools - New Fuel Pressure Gauge and Replacement Parts 97-020 MAR 10, 1997 Applies To: ALL Models New Fuel Pressure Gauge and Replacement Parts New Gauge The fuel pressure gauge with 10" hose (T/N 07406-0040001) has been discontinued. The gauge that replaces it (T/N 07406-004000A) has an easier-to-read face, a protective boot around the gauge housing, and a 48" hose. Replacement Parts Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > Tools - New Fuel Pressure Gauge and Replacement Parts > Page 1388 The replacement hose for the old gauge (24", T/N 07406-004020A) has also been discontinued. If you need a replacement hose, order the new 48" hose (T/N 07406-004020B). The new hose comes with an adapter so you can use it with the old fuel pressure gauge (T/N 07406-0040001). Before connecting the hose to the vehicle, make sure the aluminum washer on the end of the hose seals properly. If the aluminum washer doesn't seal, replace the washer. Replacement washers come in a set of five (T/N 07406-0040300). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > Page 1389 Fuel Pressure: Specifications At Curb Idle With Vacuum Hose Connected ....................................................................................................................................................... 215-265 kPa (31-38 psi) With Vacuum Hose Disconnected ................................................................................................................................................... 280-330 kPa (40-47 psi) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > Page 1390 Fuel Pressure: Testing and Inspection 1. Relieve fuel pressure. 2. Remove the service bolt on the fuel filter while holding the banjo bolt with another wrench. Attach the special tool. 3. Start the engine *. Measure the fuel pressure with the engine idling and vacuum hose of the fuel pressure regulator disconnected from the fuel pressure regulator and pinched. Pressure should be: 280-330 kPa (2.8-3.3 kg/cm2, 40-47 psi) 4. Reconnect vacuum hose to the fuel pressure regulator. Pressure should be: 215-265 kPa (2.15-2.65 kg/cm2, 31-38 psi) ^ If the engine will not start, turn the ignition switch on, wait for two seconds, turn it off, then back on again and read the fuel pressure. ^ If the fuel pressure is not as specified, first check the fuel pump. If the fuel is OK, check the following: ^ If the fuel pressure is higher than specified, inspect for: Pinched or clogged fuel return hose or piping. - Faulty fuel pressure regulator. ^ If the fuel pressure is lower than specified, inspect for: Clogged fuel filter. - Faulty fuel pressure regulator. Leakage in the fuel hoses or pipes. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Adjustments Air/Fuel Mixture: Adjustments The Air/Fuel mixture is controlled by the engine control module and is not adjustable. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications IDLE SPEED Manual transmission ............................................................................................................................ ................................................. 670 RPM [01] Automatic transmission .............................................. ........................................................................................................................... 670 RPM [01] [01] -- Transmission in Neutral or Park, headlights and cooling fan OFF. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 1397 Idle Speed: Testing and Inspection 1. Start the engine and allow it to warm-up (the radiator fan comes on). 2. Connect a tachometer to the test tachometer connector. NOTE: All electrical systems should be turned OFF. IDLE SPEED: (M/T) in neutral: (USA): 670 ± 50 rpm (Canada): 750 ± 50 rpm (A/T) in [N] or [P]: (USA): 700 ± 50 rpm (Canada): 750 ± 50 rpm 3. Adjust the idle speed, if necessary. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 1398 Idle Speed: Adjustments NOTE: ^ When the idle speed set, check the following items: The MIL has not been reported on. - Ignition timing - Spark plugs - Air cleaner - PCV system ^ (Canada) Pull the parking brake lever up. Start the engine, then check that the headlights are off. 1. Start the engine. Hold the engine at 3,000 rpm with no load (A/T in [N] or [P] position, M/T in neutral) until the radiator fan comes on, then let it idle. 2. Connect a tachometer. 3. Disconnect the 2P connector from the Idle Air Control (IAC) valve. 4. Start the engine with the accelerator pedal slightly depressed. Stabilize the rpm at 1,000, then slowly release the pedal until the engine idles. 5. Check idling in no-load conditions: headlights, blower fan, rear defogger, radiator fan, and air conditioning are not operating. Idle speed should be: M/T D15Z1 engine: 420 +/- 50 rpm Others: 420 +/- 50 rpm A/T 420 +/- 50 rpm (in [N] or [P] position) Adjust the idle speed, if necessary, by turning the idle adjusting screw. NOTE: After adjusting the idle speed in this step, check the ignition timing. If it is out of spec, go back to step 4. 6. Turn the ignition switch OFF. 7. Reconnect the 2P connector on the IAC valve, then remove BACK UP (7.5 A) fuse in the under-hood fuse/relay box for 10 seconds to reset the ECM. 8. Restart and idle the engine with no-load conditions for one minute, then check the idle speed. NOTE: (Canada) Pull the parking brake lever up. Start the engine, then check that the headlights are off. Idle speed should be: Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 1399 M/T D15Z1 engine: 600 +/- 50 rpm Others: 670 +/- 50 rpm A/T 700 +/- 50 rpm (in [N] or [P] position) 9. Idle the engine for one minute with headlights (Low) ON and check the idle speed. Idle speed should be: M/T D15Z1 engine: 700 +/- 50 rpm Others: 750 +/- 50 rpm A/T 750 +/- 50 rpm (in [N] or [P] position) 10. Turn the headlights off. Idle the engine for one minute with heater fan switch at HI and air conditioner on, then check the idle speed. Idle speed should be: M/T D15Z1 engine: 810 +/- 50 rpm Others: 810 +/- 50 rpm A/T 810 +/- 50 rpm (in [N] or [P] position) NOTE: If the idle speed is not within specification, see System Troubleshooting Guide. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component Information > Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair WARNING: Do not smoke while working on the Fuel system. Keep open flames or sparks away from your work area. Be sure to relieve fuel pressure while the Ignition Switch is off. NOTE: Before disconnecting fuel pipes or hoses, release pressure from the system by loosening the 6 mm service bolt on top of the fuel filter. 1. Disconnect the battery negative cable from the battery negative terminal. 2. Remove the fuel fill cap. 3. Use a box end wrench on the 6 mm service bolt at the fuel filter, while holding the special banjo bolt with another wrench. 4. Place a rag or shop towel over the 6 mm service bolt. 5. Slowly loosen the 6 mm service bolt one complete turn. NOTE: A fuel pressure gauge can be attached at the 6 mm service bolt hole. - Always replace the washer between the service bolt and the special banjo bolt whenever the service bolt is loosened. - Replace all washers whenever the bolts are removed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > System Check Connector <--> [Ignition Timing Connector] > Component Information > Locations > Component Locations System Check Connector: Component Locations The Service Check Connector is located behind the glove box. CAUTION: Do not use a jumper wire on the Data Link Connector. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > System Check Connector <--> [Ignition Timing Connector] > Component Information > Locations > Component Locations > Page 1415 System Check Connector: Connector Locations The Service Check Connector is located behind the glove box. CAUTION: Do not use a jumper wire on the Data Link Connector. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Timing Marks and Indicators > System Information > Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications Resistance at 20°C (68°F) ................................................................................................................... ......................................................... 25 K Ohms max Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions Ignition Cable: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 1427 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 1428 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 1429 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 1430 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 1431 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 1432 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 1433 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 1434 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 1435 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 1436 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 1437 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 1438 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 1439 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 1440 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 1441 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 1442 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 1443 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 1444 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 1445 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 1446 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 1447 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 1448 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 1449 Ignition Cable: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 1450 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 1451 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 1452 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 1453 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 1454 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 1455 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 1456 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 1457 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 1458 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 1459 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 1460 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 1461 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 1462 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 1463 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 1464 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 1465 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 1466 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 1467 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 1468 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 1469 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 1470 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 1471 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 1472 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 1473 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 1474 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 1475 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Page 1476 Ignition Cable: Testing and Inspection CAUTION: Carefully remove the ignition wires by pulling on the rubber boots. Do not bend the wires; you might break them inside. 1. Check the condition of the wire terminals. If any terminal is corroded, clean it, and if it is broken or distorted, replace the wire. 2. Connect ohmmeter probes and measure resistance. Resistance: 25 k Ohms max. at 70° F (20°C) 3. If resistance exceeds 25 k Ohms, replace the ignition wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Cap > Component Information > Testing and Inspection Distributor Cap: Testing and Inspection Check the following points, repair or replace as needed if a problem is found. 1. There must be no cracking in the cap. 2. There must be no damage to the cap's electrodes. 3. Clean away any accumulated dirt from the cap. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Testing and Inspection Ignition Rotor: Testing and Inspection Check the following points, repair or replace as needed if a problem is found. 1. There must be no cracking in the rotor. 2. There must be no damage to the rotor's electrode. 3. Clean away any accumulated dirt from the rotor. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap and Torque Spark Plug: Specifications Gap and Torque Spark Plug Gap ................................................................................................................................... ........................................................ 1.1 mm (0.043 in) Spark Plug Torque ............................................................................................................................... ......................................................... 18 Nm (13 ft lb) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap and Torque > Page 1488 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1489 Spark Plug: Testing and Inspection Spark Plug Inspection 1. Inspect the electrodes and ceramic insulator for: Burned or worn electrodes may be caused by: ^ Advanced ignition timing ^ Loose spark plug ^ Plug heat range too low ^ Insufficient cooling Fouled plug may be caused by: ^ Retarded ignition timing ^ Oil in combustion chamber ^ Incorrect spark plug gap ^ Plug heat range too high ^ Excessive idling/low speed running ^ Clogged air cleaner element ^ Deteriorated ignition coil or ignition wires 2. Adjust the gap with a suitable gapping tool. 3. Replace the plug if the center electrode is rounded as shown above. NOTE: Do not use spark plugs other than recommended types. These plugs are a new type (ISO standard). 4. Screw the plugs into the cylinder head finger tight, then torque them to 18 N-m (1.8 kg-m, 13 lb-ft). NOTE: Apply a small quantity of anti-seize compound to the plug threads before installing. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Check compression with engine at normal operating temperature and throttle in wide open position. Prior to performing test, disable ignition and fuel injection to prevent fuel from being sprayed into cylinders while cranking engine. Ensure is fully charged and that cranking speed is 250 RPM. Standard reading should be 135-184 psi. The maximum variation between cylinders is 28 psi. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications Valve Clearance Intake ................................................................................................................................................... .......................................... 0.007-0.009 inches Exhaust ................................................................................................................................................ .......................................... 0.009-0.011 inches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 1496 Valve Clearance: Adjustments VALVE CLEARANCE ADJUSTMENT NOTE: Valves should be adjusted only when the cylinder head temperature is less than 100°F (38°C). Adjustment is the same for intake and exhaust valves. ^ After adjusting, Retorque the crankshaft pulley bolt to 181 Nm (134 ft. lbs.). 1. Remove the cylinder head cover. 2. Set the No. 1 piston at TDC. "UP" mark on the camshaft pulley should be at top, and TDC marks should align with the cylinder head surface. The crankshaft pulley should be at TDC. 3. Adjust valves on No. 1 cylinder. - Intake: 0.18-0.22 mm (0.007-0.009 inch) - Exhaust: 0.23-0.27 mm (0.009-0.011 inch) 4. Loosen the locknut, and turn the adjustment screw until the feeler gauge slides back and forth with a slight amount of drag. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 1497 CAUTION: Do not overtighten the locknuts; the rocker arms are made of aluminum. 5. Tighten the locknut, and check the clearance again. Repeat the adjustment if necessary. 6. Rotate the crankshaft 180° counterclockwise (camshaft pulley turns 90°). The "UP" mark should be on the exhaust side. Adjust valves on No. 3 cylinder. 7. Rotate the crankshaft 180° counterclockwise to bring No. 4 piston to TDC. Both TDC grooves are once again visible. Adjust valves on No. 4 cylinder. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 1498 8. Rotate the crankshaft 180° counterclockwise to bring No. 2 piston to TDC. The UP" mark should be on the intake side. Adjust valves on No. 2 cylinder. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Timing Belt > Component Information > Diagrams Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Timing Belt > Component Information > Diagrams > Page 1502 Timing Belt: Testing and Inspection TIMING BELT INSPECTION NOTE: - Replace the belt if oil or coolant soaked. - Remove any oil or solvent that gets on the belt. 1. Remove the cylinder head cover. 2. Remove the timing belt upper cover. 3. Inspect the timing belt for cracks and oil or coolant soaking. 4. After inspecting, retorque the crankshaft pulley bolt to specified torque. Specified Torque: 185 N.m (18.5 kg-m, 134 lb-ft) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Timing Belt > Component Information > Diagrams > Page 1503 Timing Belt: Adjustments TIMING BELT TENSION ADJUSTMENT CAUTION: Always adjust the timing belt tension with the engine cold. NOTE: - The tensioner is spring-loaded to apply proper tension to the belt automatically after making the following adjustment. - Always rotate the crankshaft counterclockwise when viewed from the pulley side. Rotating it clockwise may result in improper adjustment of the belt tension. 1. Remove the cylinder head cover. 2. Remove the timing belt upper cover. 3. Set the No.1 piston at top dead center (TDC). 4. Loosen the adjusting bolt 180°. 5. Rotate the crankshaft counterclockwise 3-teeth on the camshaft pulley to create tension on the timing belt. 6. Make sure the timing belt and the camshaft pulley are engaged securely. 7. Torque the adjusting bolt to 45 N.m (4.5 kg-m, 33 lb-ft). 8. After adjusting, retorque the crankshaft pulley bolt to specified torque. Specified Torque: 185 N.m (18.5 kg-m, 134 lb-ft) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Timing Belt > Component Information > Diagrams > Page 1504 Timing Belt: Service and Repair TIMING BELT REMOVAL CAUTION: Inspect the water pump when replacing the timing belt. NOTE: Turn the crankshaft so that No.1 piston is at top-dead-center. - Before removing the timing belt, mark its direction of rotation if it to be reused. 1. Remove the splash shield. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Timing Belt > Component Information > Diagrams > Page 1505 2. Remove the power steering pump. - Do not disconnect the P/S hoses. 3. On vehicles with A/C remove the A/C compressor adjusting pulley with bracket and the belt. 4. Remove the P/S bracket. 5. Loosen the alternator adjusting bolt and pivot nut, then remove the belt. 6. Remove the cruise control actuator. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Timing Belt > Component Information > Diagrams > Page 1506 7. Remove the engine support nuts. Loosen the mount bolt and pivot the side engine mount out of the way. 8. Remove the cylinder head cover. 9. Remove the timing belt upper cover. 10. Remove the special bolt and crankshaft pulley. 11. Remove the timing belt upper cover and the lower cover. 12. Loosen the timing belt adjusting bolt 180°. 13. Push the tensioner to release tension from the belt, then retighten the adjusting bolt. 14. Remove the timing belt from the pulleys. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Timing Belt > Component Information > Diagrams > Page 1507 TIMING BELT INSTALLATION 1. Install the timing belt in the reverse order of removal; Only key points are described here. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Timing Belt > Component Information > Diagrams > Page 1508 2. Position the crankshaft and the camshaft pulleys as shown before installing the timing belt. A. Set the crankshaft so that the No.1 piston is at top dead center (TDC). Align the groove on the teeth side of the timing belt drive pulley to the pointer on the oil pump. B. Align the TDC marks on the camshaft pulley with the cylinder head upper surface. 3. Install the timing belt tightly in the sequence shown. (1) Timing belt drive pulley (crankshaft) -> (2) Adjusting pulley -> (3) Water pump pulley -> (4) Camshaft pulley. 4. Loosen the adjusting bolt, and retighten it after tensioning the belt. 5. Rotate the crankshaft about 4 or 6 turns counterclockwise so that the belt positions on the pulleys. 6. Adjust the timing belt tension. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Timing Belt > Component Information > Diagrams > Page 1509 Crankshaft Pulley Camshaft Pulley 7. Check the crankshaft pulley and the camshaft pulley at TDC. 8. If the camshaft pulley is not positioned at TDC remove the timing belt and adjust the positioning and repeat the installation procedure and reinstall the timing belt. After installation, adjust the tension of each belt. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Tools Belt Tension Gauge Calibration and Repair Drive Belt: Technical Service Bulletins Tools - Belt Tension Gauge Calibration and Repair Bulletin No. 96-014 Issue Date Feb. 20, 1996 Model ALL Applicable To ALL File Under SPECIAL TOOLS Belt Tension Gauge Calibration and Repair Tensioning the engine belts properly with the belt tension gauge (T/N 07JGG-001010A) is critical to bearing life of the A/C compressor, alternator, etc. Calibration of the belt tension gauge should be checked regularly. CALIBRATION A Belt Tension Gauge Checker, needed for checking the calibration of the belt tension gauge, is now available. One checker is being automatically shipped to each dealership. Additional checkers may be ordered through normal parts ordering channels. The part number is 07TGG-001010A. Procedure 1. Push the handle and slide the checker into the gauge. Position the checker as shown. 2. Release the handle and read the tension value on the Kg scale. 3. Compare your reading to the value etched on the checker. Your gauge is in calibration if it is within +/- 3 kg of the checker value. If your belt tension gauge is out of calibration, you cannot recalibrate it yourself. Contact America Kowa Seiki about sending it for recalibration. REPLACEMENT PARTS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Tools Belt Tension Gauge Calibration and Repair > Page 1514 If your belt tension gauge is damaged, replacement parts are available from America Kowa Seiki. They are: REPAIR AND CALIBRATION INFORMATION To order replacement parts for a gauge, contact: America Kowa Seiki 20013 S. Rancho Way Rancho Dominguez, CA 90220 (800) 824-9655 To return your belt tension gauge for calibration: ^ Contact America Kowa Seiki for authorization and shipping instructions. ^ Pack the belt tension gauge in a suitable box. Use "bubble pack" to protect the gauge. ^ Ship according to their instructions. America Kowa Seiki will charge a fixed fee to inspect, clean and calibrate the belt tension gauge, and return it via UPS ground. Any repair parts needed are extra. The gauge will be returned within 15 days. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1515 Drive Belt: Specifications Air Conditioning Deflection, Inches [01]: New ..................................................................................................................................................... .................................................... 0.20-0.28 Used ............................................................................... ......................................................................................................................... 0.26-0.41 Alternator Deflection, Inches [01]: New ..................................................................................................................................................... .................................................... 0.22-0.31 Used ............................................................................... ......................................................................................................................... 0.28-0.41 Power Steering Deflection, Inches [01]: New ..................................................................................................................................................... .................................................... 0.24-0.37 Used ............................................................................... ......................................................................................................................... 0.31-0.47 [01] -- Measured using 22 ft. lbs. force. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Component Information > Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair WARNING: Do not smoke while working on the Fuel system. Keep open flames or sparks away from your work area. Be sure to relieve fuel pressure while the Ignition Switch is off. NOTE: Before disconnecting fuel pipes or hoses, release pressure from the system by loosening the 6 mm service bolt on top of the fuel filter. 1. Disconnect the battery negative cable from the battery negative terminal. 2. Remove the fuel fill cap. 3. Use a box end wrench on the 6 mm service bolt at the fuel filter, while holding the special banjo bolt with another wrench. 4. Place a rag or shop towel over the 6 mm service bolt. 5. Slowly loosen the 6 mm service bolt one complete turn. NOTE: A fuel pressure gauge can be attached at the 6 mm service bolt hole. - Always replace the washer between the service bolt and the special banjo bolt whenever the service bolt is loosened. - Replace all washers whenever the bolts are removed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Hoses > System Information > Service Precautions Hoses: Service Precautions SERVICE PRECAUTIONS To prevent vehicle damage, always observe the following precautions: After servicing a hose, check for leaks before and after test driving the vehicle. - Always use the correct size hose. Do not use standard sized hose in place of metric hose or vice versa. Always use the correct type of hose. Never use vacuum hose in place of fuel hose. Never use heater hose in place of PCV hose. - When replacing hoses which are attached to the engine on one end and the frame or body on the other end, always leave sufficient length to compensate for engine movement (from torque). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications Fluid type DOT 3 or 4 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Coolant Capacity, Quarts: Man. Transmission .............................................................................................................................. .................................................................. 4.76 Auto. Transmission ................................................... .............................................................................................................................................. 4.6 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1535 Coolant: Fluid Type Specifications Coolant/Anti-freeze Ethylene Glycol Based Coolant Concentration Minimum 50 % Maximum 60 % Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications TYPE ................................................................................................................................................... ............................................................................. AF CAPACITY, Refill*: Accord 4cyl........................................................................................................................................... ........................................ 2.4 liters 2.5 quarts V6 ........................................................................................................................................................ ................................... 2.7 liters 2.9 quarts Civic, Del Sol ....................................................................................................................................... ........................................ 2.7 liters 2.9 quarts Prelude ................................................................................................................................................ .......................................... 2.4 liters 2.5 quarts Odyssey, Oasis ................................................................................................................................... ........................................... 2.4 liters 2.5 quarts *With the engine at operating temperature, shift transmission through all gears. Turn engine off and check fluid level within 1 minute. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 1540 Fluid - A/T: Fluid Type Specifications KEY TO LUBRICATION ABBREVIATIONS NOTE: Some manufacturer lubricant names may differ from the following list. If the manufacturer does not recommend a specific lubricant, use the following. AF Dexron(r)-III Automatic Transmission Fluid AP ATF-PLUS(r) Automatic Transmission Fluid BJ Suspension Lubricant BL Brake Lubricant CC Motor Oil, API Service CC CD Motor Oil, API Service CD CE Motor Oil, API Service CE CF-4 Motor Oil, API Service CF-4 DC Distributor Cam Lubricant EC Ethylene Glycol Coolant EP Extreme Pressure Gear Oil FA Automatic Transmission Fluid, Type F GC Wheel Bearing Grease, NLGI Classification GC GF-1 Motor Oil, API Service GF-1 (Starburst) GL-1 Gear Oil, API Service GL-1 GL-4 Gear Oil, API Service GL-4 GL-5 Gear Oil, API Service GL-5 GL-5* GL-5 Gear Oil for Limited Slip Differentials GLS Gear Lubricant, Special HB Hydraulic Brake Fluid, SAE J1703, DOT-3 or 4 HBH Hydraulic Brake Fluid, Extra Heavy Duty HG High Temperature Grease HP Hypoid Gear Oil HP* Hypoid Gear Oil for Limited Slip or Traction-Lok Differentials LB Chassis Grease, NLGI Classification LB LL Steering Linkage Lubricant LM Lithium Multipurpose Grease MA Mercon(r) Automatic Transmission Fluid MH Manifold Heat Riser Solvent MO Motor Oil, Any API Service Classification PC Carburetor Cleaner PS Power Steering Fluid SF Motor Oil, API service SF SG Motor Oil, API service SG SH Motor Oil, API service SH SLF Special Lubricant - Fluid SLS Special Lubricant - Spray WB Wheel Bearing Grease Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1541 Fluid - A/T: Service and Repair Checking NOTE: Check the fluid level with the engine at normal operating temperature (the cooling fan comes on). 1. Park the car on level ground. Shut off the engine. 2. Remove the dipstick (yellow loop) from the transmission and wipe it with a clean cloth. 3. Insert the dipstick into the transmission. 4. Remove the dipstick and check the fluid level. It should be between the upper and lower marks. 5. If the level is below the lower mark, add fluid into the tube to bring it to the upper mark. Use Honda Premium Formula Automatic Transmission Fluid or an equivalent DEXRON® II Automatic Transmission Fluid (AT F) only. 6. Insert the dipstick back into the transmission. Changing Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1542 1.Bring the transmission up to operating temperature by driving the car. Park the car on level ground, turn the engine off, then remove drain plug. 2.Reinstall the drain plug with a new washer, then refill the transmission to the upper mark on the dipstick. Automatic Transmission Fluid Capacity: 2.7 (2.9 US qt , 2.4 Imp at) at change 5.9 (6.2 US at , 5.2 Imp at) at overhaul Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications TYPE 1992-95 ..................................................................................................................................... ............................................................................. SG TYPE 1996 .......................................................................................................................................... ........................................................................... GLS Above 20°F (-7°C), 1992 ..................................................................................................................... .............................................................................. 30 Above 0°F (-18°C), 1992 ................................. ......................................................................................................................................................... 20W-40 All temperatures ..................................................................................................................... ................................................................ 10W-30*, 10W-40* * Preferred CAPACITY, Refill: Accord ................................................................................................................................................. ............................................ 1.9 liters 4.0 pints Civic, Del Sol ....................................................................................................................................... ........................................... 1.8 liters 3.8 pints VTEC 1992-95...................................................................................................................................... ..................................... 2.2 liters 4.6 pints Prelude ................................................................................................................................................ ............................................ 1.9 liters 4.0 pints Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 1547 Fluid - M/T: Fluid Type Specifications KEY TO LUBRICATION ABBREVIATIONS NOTE: Some manufacturer lubricant names may differ from the following list. If the manufacturer does not recommend a specific lubricant, use the following. AF Dexron(r)-III Automatic Transmission Fluid AP ATF-PLUS(r) Automatic Transmission Fluid BJ Suspension Lubricant BL Brake Lubricant CC Motor Oil, API Service CC CD Motor Oil, API Service CD CE Motor Oil, API Service CE CF-4 Motor Oil, API Service CF-4 DC Distributor Cam Lubricant EC Ethylene Glycol Coolant EP Extreme Pressure Gear Oil FA Automatic Transmission Fluid, Type F GC Wheel Bearing Grease, NLGI Classification GC GF-1 Motor Oil, API Service GF-1 (Starburst) GL-1 Gear Oil, API Service GL-1 GL-4 Gear Oil, API Service GL-4 GL-5 Gear Oil, API Service GL-5 GL-5* GL-5 Gear Oil for Limited Slip Differentials GLS Gear Lubricant, Special HB Hydraulic Brake Fluid, SAE J1703, DOT-3 or 4 HBH Hydraulic Brake Fluid, Extra Heavy Duty HG High Temperature Grease HP Hypoid Gear Oil HP* Hypoid Gear Oil for Limited Slip or Traction-Lok Differentials LB Chassis Grease, NLGI Classification LB LL Steering Linkage Lubricant LM Lithium Multipurpose Grease MA Mercon(r) Automatic Transmission Fluid MH Manifold Heat Riser Solvent MO Motor Oil, Any API Service Classification PC Carburetor Cleaner PS Power Steering Fluid SF Motor Oil, API service SF SG Motor Oil, API service SG SH Motor Oil, API service SH SLF Special Lubricant - Fluid SLS Special Lubricant - Spray WB Wheel Bearing Grease Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Page 1548 Fluid - M/T: Service and Repair NOTE: Check the oil with the engine OFF, and the car on level ground. 1. Remove the oil filler plug, then check the level and condition of the oil. 2. The oil level must be up to the filler hole. If it is below the hole, add oil until it runs out, then reinstall the oil filler plug. 3. If the transmission oil is dirty, remove the drain plug and drain the oil. 4. Reinstall the drain plug with a new washer, and refill the transmission oil to the proper level. NOTE: The drain plug washer should be replaced at every oil change. 5. Reinstall the oil filler plug with a new washer. Oil Capacity 1.8l (1.9 US qt, 1.6 Imp qt) at oil change. 1.9l (2.0 US qt, 1.7 Imp qt) at overhaul. Use only SAE 1OW-30 or 1OW-40, SF or SG grade. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine - Oil Recommendation GF-4 Standard Engine Oil: Technical Service Bulletins Engine - Oil Recommendation GF-4 Standard SOURCE: Honda Service News TITLE: Use ONLY New GF-4 Standard Engine Oil APPLIES TO: All Models SERVICE TIP: There's a new performance standard for engine oil: GF-4. It was jointly developed by automotive and oil experts, and it represents a significant performance upgrade and improvement in fuel economy. GF-4 engine oils must pass grueling tests totaling over 500 hours. On top of this, Honda Genuine engine oils are also tested to ensure specific compatibility with Honda vehicles. GF-4 engine oil is compatible with all current and earlier model year Honda cars and trucks. It also provides these added benefits: - Improved oxidation resistance (reduced thickening of the oil) - Improved deposit protection and better wear protection - Better low-temperature performance over the life of the oil - Environmental protection by extending the life of emissions systems While Honda has upgraded its engine oil to GF-4, other brands may not yet be at this new standard. Keep in mind you must use Honda Genuine engine oil for all warranty repairs. If you use some other brand of oil for non-warranty repairs, make sure that oil meets the GF-4 standard. We recommend you stop using non-GF-4 engine oils and check with your supplier that you're purchasing GF-4 oil. Engine oil produced after April 1, 2005, that meets the GF-4 standard, must post this starburst certification mark on the container. Always look for this mark; some oil container labels won't specifically refer to GF-4. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil Capacity For Engine Overhaul ........................................................................................................................................................... 4.0 L (4.2 US qts. 3.5 Imp.qt) For Oil Change, Including Filter ....................................................................................................................................... 3.3 L (3.5 US qts. 2.9 Imp.qts) New standard for engine oil, GF-4. See TSB SN050109 for Honda Service News 050109 for additional information. API Service Grade ............................................................................................................................................ SG or SH "Energy Conserving II" grade oil. Specified viscosities: SAE 5W-30 (Preferred) SAE 10W-30 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1555 Engine Oil: Fluid Type Specifications Engine Oil Capacity For Engine Overhaul ........................................................................................................................................................... 4.0 L (4.2 US qts. 3.5 Imp.qt) For Oil Change, Including Filter ....................................................................................................................................... 3.3 L (3.5 US qts. 2.9 Imp.qts) New standard for engine oil, GF-4. See TSB SN050109 for Honda Service News 050109 for additional information. API Service Grade ............................................................................................................................................ SG or SH "Energy Conserving II" grade oil. Specified viscosities: SAE 5W-30 (Preferred) SAE 10W-30 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications Power Steering Fluid: Specifications Fluid Type ............................................................................................................................................ ....................... Genuine Honda Power Steering Fluid Always use Genuine Honda Power Steering Fluid. Using any other type of power steering fluid or automatic transmission fluid can cause increased wear and poor steering in cold weather. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Leak Detection Refrigerant: Technical Service Bulletins A/C - Refrigerant Leak Detection 07-030 October 12, 2007 Applies To: ALL Vehicles With Conventional A/C Compressors A/C Leak Detection (Supersedes 07-030, dated June 15, 2007, to update the information marked by asterisks) The OPTIMAX Jr. (TM)A/C Leak Detection Kit for Honda vehicles, P/N TRP124893, is a new required tool. The kit is used to add small amounts of dye to A/C systems to help locate smaller leaks that an electronic leak detector might not find. When searching for leaks, always begin by using an electronic leak detector. Refer to Service Bulletin 97-027, Denso HLD-100 Halogen Leak Detector; for tips on using this tool, then follow up with the OPTIMAX Jr. This new detection kit complements but does not replace the electronic detector. The kit contains: ^ TRP8640CS, OPTIMAX Jr. (TM) cordless, fluorescent leak detection flashlight lamp (includes 3 standard AA batteries) ^ TRP38600601, (6) 0.06 oz. (1.7 g) Tracer-Stick(R) R134a/PAG A/C dye capsules with ID labels ^ TRP3887, R-134a Universal Connect Set(TM) ^ TRP120884, GLO-AWAY(TM) dye cleaner ^ TRP9940, fluorescence-enhancing glasses ^ TRP1143, (1) empty Tracer-Stick dye capsule ORDERING INFO *One OPTIMAX Jr. A/C Leak Detection Kit was shipped to each current dealer as a required special tool. Additional kits and replacement capsules may be ordered through the Honda Tool and Equipment Program. On the iN, click on Service, Service Bay, Tool and Equipment Program, Online Catalog tab, and Air Conditioning Equipment, or call.* NOTICE ^ Do not use leak-trace dye in any Honda hybrid vehicle equipped with a dual-scroll compressor This can increase the chance of electric shock. The compressor is easily identified by the orange high-voltage cable that is connected to the compressor body. ^ Only Tracer-Stick single-dose fluorescent dye capsules from Tracer Products (Tracerline(R)) are approved for use in Honda vehicles. Other dyes contain solvents that may contaminate the system's refrigerant oil, leading to component failure. ^ Adding excessive amounts of dye can lead to compressor damage and failure. USING THE OPTIMAX JR. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Leak Detection > Page 1563 1. Before adding any leak-detection dye, check to see if there is dye in the system now. ^ Check for a label in the engine compartment indicating that fluorescent leak-detection dye has been added to the system. ^ Dye may have been added even though no label is present. To confirm this: - Put on the fluorescence-enhancing glasses, and remove the low-side service port sealing cap. - Direct the ultraviolet lamp into the valve stem area. If dye has been previously added, the lubricant traces will have a bright yellow fluorescent glow. You may need to press the port's valve stem briefly to release some lubricant and dye from the system. ^ If there is no dye in the system, go to step 2. ^ If there is dye in the system, go to step 5. Do not add more dye. 2. Add the dye. NOTE: Air and moisture must be evacuated from the universal connect set if it is being used for the first time, or if it has been stored with the control valve open. If the air and moisture have been evacuated, go to step 3; otherwise do the following: (a) Attach the empty dye capsule (provided in the dye kit) to the control valve fitting. (b) Attach the service valve fitting (provided in the kit) to the empty dye capsule. (c) Attach the low-side hose of the A/C recovery and charging station, and open the quick coupler's hand-wheel valve. Then open the control valve (black knob) on the universal connect set. (d) Following the manufacturer's instructions for your recovery and charging station, evacuate the universal connect set for approximately 3 minutes. (e) When evacuation is complete, be sure the set's control valve is closed (finger tight), and disconnect the NC recovery and charging station. (f) Remove the service valve fitting and the empty dye capsule from the set, and store them for future use. NOTE: ^ Check the refrigerant charge level. There must be enough refrigerant in the system to operate the A/C compressor and to circulate refrigerant oil. ^ If the refrigerant charge is too low, recover the remaining amount and recharge the system before adding any dye. (g) Start the vehicle and operate the A/C system. Follow your A/C refrigerant recovery and charging station's operating instructions for low-side charging to install the dye. * NOTE: Only 0.05 lb (0.02 kg) of refrigerant is needed to push the dye into the A/C system.* (h) Once the refrigerant charge is programmed, open the control valve on the set to allow the dye to enter the system. (i) After the dye capsule clears, allow the low-side of the A/C system to reach its lowest operating pressure, then quickly close both the service equipment's low-side coupler valve and the control valve on the set. (j) Remove the set from the vehicle by releasing its quick coupler. Remove the empty dye capsule from the service valve fitting. Return the hose, control valve, and service-valve fitting to the storage case. * NOTE: Store the hose with the control valve closed. This will retain a small amount of refrigerant in the hose so it does not have to be evacuated the next time you use it.* (k) Fill out an identification label (provided in the kit), and attach it to a location near the A/C charge label. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Leak Detection > Page 1564 3. Connect the universal connect set and the Tracer- Stick dye capsule: (a) Be sure the quick coupler and control valves on the set are closed. (b) Remove the low-side service port sealing cap, and connect the set to the low-side service port using the quick coupler. (c) Hold a new dye capsule so that the embossed arrow is pointing up. Remove the black end cap, and carefully attach the capsule to the control valve fitting. NOTE: The capsule must be held with the embossed arrow pointing up or the dye will leak out of the capsule. (d) Turn the capsule so the embossed arrow is pointing down. Remove the orange end cap, and carefully attach the service valve fitting provided in the kit (finger tight). NOTE: The capsule must be held with the embossed arrow pointing down or the dye will leak out. 4. Connect the NC service equipment: With the universal connect set and dye capsule attached to the vehicle's low-side service port, connect the A/C refrigerant recovery and charging station's low-side hose quick coupler to the service valve fitting. Open the blue hand-wheel valves on both quick couplers. Leave the control valve (black knob) on the universal connect set closed. NOTE: * ^ If you have recovered refrigerant to weigh it as part of your diagnostics, or if there is a low charge, it is more efficient to recharge the system using normal procedures before installing the universal connect set. Dye can then be added using approximately 0.05 lb (0.02 kg) of refrigerant.* ^ You do not need to connect the service equipment's high-side hose to the vehicle to install the dye. If the high-side hose is connected, make sure its coupler valve is closed before proceeding. ^ Do not use the A/C recovery and charging station to recover or evacuate the A/C system when a full dye capsule is attached. The dye will be drawn into the service equipment instead of being added to the vehicle's A/C system. 5. Inspect the A/C system for leaks: (a) Run the A/C system for at least 15 minutes to circulate the dye through the system. Large leaks will be seen immediately as a fluorescent yellow glow. Smaller leaks may require at least 24 hours of vehicle operation before they become visible. Operate the A/C system as much as possible during this time to keep the dye circulating. (b) Stop the vehicle's engine and inspect the system for leaks using the ultraviolet (UV) lamp and fluorescence-enhancing glasses from the kit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Leak Detection > Page 1565 Low ambient light conditions (a dark work area) will aid in locating the leak. NOTE: Not all UV lamps work well with all types of fluorescent dye. Use only the lamp provided in the kit to inspect for leaks. (c) Inspect the entire system. Be sure to check these locations: ^ damaged and corroded areas ^ fittings ^ hose-to-line couplings ^ refrigerant controls ^ service ports ^ brazed or welded areas ^ areas near attachment points (d) Check for evaporator leaks by illuminating the evaporator drain tube area with the UV lamp and glasses. (e) After repairing a leak, remove any fluorescent residue using the GLO-AWAY dye cleaner from the kit and hot water (follow the instructions on the bottle). Disclaimer Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Refrigerant: Capacity, Lbs. ...................................................................................................................................... ................................................................... 1.2 Type ........................................................................... ....................................................................................................................................... R-134a Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 1568 Refrigerant: Fluid Type Specifications A/C Refrigerant .................................................................................................................................... ...................................................................... R-134a Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Refrigerant Oil Type: SP-10: P/N 38899-P13-AO1 Refrigerant Oil Capacity: Condenser: 20 ml (2/3 fl.oz, 0.7 imp.oz) Evaporator: 45 ml (1 1/2 fl.oz, 1.6 imp.oz) Line or hose: 10 ml (1/3 fl.oz, 0.4 imp.oz) Receiver/Dryer: 10 ml (1/3 fl.oz, 0.4 imp.oz) Leakage repair: 25 ml (5/6 fl.oz, 0.9 imp.oz) Compressor: For compressor replacement, subtract the volume of oil drained from the removed compressor from 120 ml (4 fl.oz, 4.2 imp.oz), and drain the calculated volume of oil from the new compressor. 120 ml (4 fl.oz, 4.2 imp.oz) - Volume of removed compressor = Volume to drain from new compressor. NOTE: Even if no oil is drained from the removed compressor, don't drain more than 50 ml (1 2/3 fl.oz, 1.8 imp.oz) from the new compressor. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 1573 Refrigerant Oil: Fluid Type Specifications Refrigerant Oil Type ............................................................................................................................ ......................................................................... SP-10 Honda PN ....................................................... ........................................................................................................................................ 38897-P13-A01AH Honda Code ......................................................................................................... .................................................................................................... 5023627 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > System Bleeding Brake Bleeding: Service and Repair System Bleeding Anti-Lock Brake System Anti-Lock Brake Bleeding See: With Anti-Lock Brakes (Using ALB Checker) With Anti-Lock Brakes (Using ALB Checker) Park vehicle on level ground with wheels blocked. When bleeding brakes, put manual transaxle in the Neutral position and automatic transaxle in the Park position. 1. With ignition switch Off, disconnect 6-P inspection connector from connector cover on the crossmember under passenger seat and connect it to anti-lock brake checker tool Nos. 07HAJ-SG0010A or 07HAJ-SG0010B, or equivalents. 2. Fill modulator reservoir to MAX level and install reservoir cap. 3. Start engine and allow it to idle for a few minutes, then shut engine off. Check fluid in modulator reservoir and refill to MAX level if necessary. Fig. 86 Bleeding High Pressure Fluid At Maintenance Bleeder 4. Bleed high pressure fluid from maintenance bleeder with bleeder wrench tool No. 07HAA-SG00101, or equivalent, Fig. 86. 5. Refill modulator reservoir to MAX level and install reservoir cap. 6. Turn mode selector switch on checker to 2. 7. While depressing brake pedal firmly, push start test switch to operate modulator. There should be kickback on brake pedal. If there is no kickback, repeat bleeding sequence as outlined above. 8. Turn mode selector switch on checker to 3, 4 and 5. At each test mode position, refill modulator reservoir to MAX level and install reservoir cap. 9. Refill modulator reservoir to MAX level and install reservoir cap. Disconnect ALB checker before driving car. A collision can result from a reduction, or complete loss of braking ability. Without Anti-Lock Brakes CAUTION: - Always use Genuine Honda DOT 3 Brake Fluid. Using a non-Honda brake fluid can cause corrosion and decrease the life of the system. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > System Bleeding > Page 1578 - Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid. - Do not spill brake fluid on the vehicle, it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water. NOTE: The reservoir on the master cylinder must be at the MAX (upper) level mark at the start of the bleeding procedure and checked after bleeding each brake caliper. Add fluid as required. 1. Make sure the brake fluid level in the reservoir is at the MAX (upper) level line. 2. Have someone slowly pump the brake pedal several times, then apply steady pressure. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > System Bleeding > Page 1579 3. Loosen the brake bleed screw to allow air to escape from the system. Then tighten the bleed screw securely. Brake Bleeding Sequence 4. Repeat the procedure for each wheel in the sequence shown until air bubbles no longer appear in the fluid. 5. Refill the master cylinder reservoir to the MAX (upper) level line. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > System Bleeding > Page 1580 Brake Bleeding: Service and Repair ABS Hydraulic Component Bleeding and Fluid Service Relieving Accumulator/Line Pressure WARNING: Use the Bleeder T-wrench before disassembling the parts shaded in the illustration Collecting High-pressure Fluid Into Reservoir Through Maintenance Bleeder - Open the hood. - Remove the red cap from the bleeder on the modulator body. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > System Bleeding > Page 1581 Fig. 81 Brake System Pressure Relief - Install the special tool on the maintenance bleeder, and turn it out slowly 90° to collect high-pressure fluid into the reservoir. Turn the special tool out one complete turn to drain the brake fluid thoroughly. - Retighten the maintenance bleeder, and discard the fluid. - Reinstall the red cap. Brake Fluid Change Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > System Bleeding > Page 1582 Fig. 85 Draining Brake Fluid Reservoir W/Syringe 1. Brake fluid may be sucked out through the top of modulator reservoir with a syringe. It may also be drained through the pump joint after disconnecting pump hose, Fig. 85. 2. Loosen master cylinder bleed screw and pump brake pedal to drain brake fluid from master cylinder. WARNING: - High-pressure fluid will squirt out if the shaded hose and pipe are removed. - To drain high-pressure brake fluid. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Specifications Air Bag(s) Arming and Disarming: Specifications Component .......................................................................................................................................... ....................................................... Torque/Ft. Lbs. Dash Sensor Mounting Bolts .............................. .............................................................................................................................................................. .. 16 Driver Side Air Bag Assembly To Steering Wheel Bolts ................................................................................................................................................. 7.2 Passenger Side Air Bag Mounting Nuts & Bolts .................................................................................. ............................................................................. 7.2 SRS Unit Mounting Bolts ................................. .............................................................................................................................................................. .. 7.2 Steering Wheel To Column Steering Shaft Nut .......................................................................... ....................................................................................... 36 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Specifications > Page 1586 Air Bag(s) Arming and Disarming: Service Precautions 1. On models with 3-P SRS connectors, install red short connectors on air bags prior to disconnecting any part of SRS wiring harness. 2-P SRS connectors automatically short when disconnected. 2. Always use test harnesses. Do not use test probes directly on component connector pins or wires. 3. When connecting any test harnesses, push connectors straight in until secure. Do not bend connector pins. 4. Always keep red short connector on air bag connector when harness is disconnected. 5. Always store air bag assembly with pad surface facing upward. 6. Do not attempt to disassemble air bag assembly. 7. An air bag that has been deployed cannot be repaired or reused. 8. Keep air bag assembly free of oil and grease. 9. Do not expose air bag assembly to temperatures above 212°F. 10. Do not use SRS components from another vehicle. Always install new replacement components. 11. Do not paint air bag assembly to correct cosmetic flaws. It must be replaced. 12. Inspect all components prior to installation. Do not install any that appear to have been improperly handled or stored or that show any signs of damage. 13. When repairing vehicle, system should be disarmed as outlined under Technician Safety Information. 14. When performing service procedures, do not expose sensors or wiring or other SRS components to heat guns, welding or spray guns. 15. SRS wiring should not be spliced, soldered or repaired. 16. Use only special digital multimeter tool No. KS-AHM-32-003, or equivalent, digital multimeter with 0.0 mA or smaller output when switched to lowest ohmmeter range to inspect system. Analog or testers with higher outputs can damage circuits or cause accidental air bag deployment and, if equipped, seat belt pretensioner activation. 17. Do not bump SRS unit whenever ignition is turned On, or has been Off for less than three minutes. Unwanted deployment could result. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Specifications > Page 1587 Air Bag(s) Arming and Disarming: Service and Repair The Supplemental Restraint System (SRS) must be disarmed prior to disconnecting any electrical connectors or servicing any system components or items located near SRS electrical connectors. SRS electrical wiring can be identified by its yellow outer protective coating. To disarm the SRS, proceed as follows: 1. Obtain five-digit radio theft protection code number. 2. Disconnect battery ground cable, then the positive cable. Fig. 1 Driver Air Bag Disarming 3. After disconnecting cables, wait at least three minutes with ignition turned Off before disconnecting any SRS electrical connectors. This will allow air bag system back-up circuit capacitor to discharge. 4. Remove steering wheel access panel and disconnect electrical connector located between air bag and cable reel, Fig. 1 5. Remove glove compartment and access panel. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Specifications > Page 1588 Fig. 4 Passenger Air Bag Disarming 6. Disconnect front passenger air bag 3-P connector from SRS main harness and connect red short connector, Fig. 4. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Specifications > Page 1589 Fig. 12 Fuse Panel/SRS Connector 7. Using thin blade screwdriver, lift SRS to under-instrument panel fuse connector lid, Fig. 12, then press tab down and slide connector out. 8. Reverse procedure to reactivate system, noting following: a. Slide harness electrical connector onto fuse panel connections until it clicks, then close connector lid. b. Ensure all red short connectors have been removed and placed in their holders. c. Prior to connecting battery ground and positive cables, ensure all supplemental restraint system electrical connectors have been properly connected. d. After battery cables have been connected, turn ignition switch to On position. SRS indicator lamp should light for approximately six seconds. If lamp does not light or remains on longer than six seconds, A SYSTEM MALFUNCTION IS INDICATED. Refer to Testing and Inspection / Procedures See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview e. Turn radio control to On. When word Code appears on display panel, enter five-digit theft protection code number. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Under-Dash Fuse/Relay Box Fuse: Locations Under-Dash Fuse/Relay Box Photo Behind Left Side Of Dash Under Dash Fuse/Relay Box Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Under-Dash Fuse/Relay Box > Page 1595 Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Under-Dash Fuse/Relay Box > Page 1596 Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 2 Of 3) Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 3 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Under-Dash Fuse/Relay Box > Page 1597 Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 3 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Under-Dash Fuse/Relay Box > Page 1598 Fuse: Locations Under-Hood Fuse/Relay Box Right Rear Corner Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Under-Dash Fuse/Relay Box > Page 1599 Fuse: Locations Under-Hood ABS Fuse/Relay Box Fuse/Relay Information-Under-hood ABS Fuse/Relay Box Right Side Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Under Dash Fuse/Relay Box Fuse: Application and ID Under Dash Fuse/Relay Box Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 1 Of 3) Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Under Dash Fuse/Relay Box > Page 1602 Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 2 Of 3) Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 3 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Under Dash Fuse/Relay Box > Page 1603 Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 3 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Under Dash Fuse/Relay Box > Page 1604 Fuse: Application and ID Under-Dash Fuse/Relay Box Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 1 Of 3) Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Under Dash Fuse/Relay Box > Page 1605 Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 2 Of 3) Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 3 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Under Dash Fuse/Relay Box > Page 1606 Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 3 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Under Dash Fuse/Relay Box > Page 1607 Fuse: Application and ID Under-Hood ABS Fuse/Relay Box Fuse/Relay Information-Under-hood ABS Fuse/Relay Box Fuse/Relay Information-Under-hood ABS Fuse/Relay Box Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Under Dash Fuse/Relay Box > Page 1608 Fuse: Application and ID Under-Hood Fuse/Relay Box Fuse/Relay Information-Under-hood Fuse/Relay Box (Part 1 Of 2) Fuse/Relay Information-Under-hood Fuse/Relay Box (Part 1 Of 2) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Under Dash Fuse/Relay Box > Page 1609 Fuse/Relay Information-Under-hood Fuse/Relay Box (Part 2 Of 2) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > SRS Fuse Block Fuse Block: Locations SRS Fuse Block Behind Left Side Of Dash Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > SRS Fuse Block > Page 1614 Fuse Block: Locations Under-Dash Fuse/Relay Box Behind Left Side Of Dash Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > SRS Fuse Block > Page 1615 Fuse Block: Locations Under-Hood ABS Fuse/Relay Box Right Side Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > SRS Fuse Block > Page 1616 Fuse Block: Locations Under-Hood Fuse/Relay Box Right Rear Corner Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Under-Hood ABS Fuse/Relay Box Fuse Block: Application and ID Under-Hood ABS Fuse/Relay Box Fuse/Relay Information-Under-hood ABS Fuse/Relay Box Fuse/Relay Information-Under-hood ABS Fuse/Relay Box Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Under-Hood ABS Fuse/Relay Box > Page 1619 Fuse Block: Application and ID Under-Dash Fuse/Relay Box Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 1 Of 3) Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Under-Hood ABS Fuse/Relay Box > Page 1620 Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 2 Of 3) Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 3 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Under-Hood ABS Fuse/Relay Box > Page 1621 Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 3 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Under-Hood ABS Fuse/Relay Box > Page 1622 Fuse Block: Application and ID Under-Hood Fuse/Relay Box Fuse/Relay Information-Under-hood Fuse/Relay Box (Part 1 Of 2) Fuse/Relay Information-Under-hood Fuse/Relay Box (Part 1 Of 2) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Under-Hood ABS Fuse/Relay Box > Page 1623 Fuse/Relay Information-Under-hood Fuse/Relay Box (Part 2 Of 2) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Electrical Load Detector (ELD) Unit Relay Box: Locations Electrical Load Detector (ELD) Unit Bottom Of Under-hood Fuse/Relay Box Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Electrical Load Detector (ELD) Unit > Page 1628 Relay Box: Locations Under-Dash Fuse/Relay Box Photo Behind Left Side Of Dash Under Dash Fuse/Relay Box Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Electrical Load Detector (ELD) Unit > Page 1629 Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Electrical Load Detector (ELD) Unit > Page 1630 Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 2 Of 3) Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 3 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Electrical Load Detector (ELD) Unit > Page 1631 Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 3 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Electrical Load Detector (ELD) Unit > Page 1632 Relay Box: Locations Under-Hood ABS Fuse/Relay Box Photo Right Side Of Engine Compartment Fuse/Relay Information-Under-hood ABS Fuse/Relay Box Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Electrical Load Detector (ELD) Unit > Page 1633 Fuse/Relay Information-Under-hood ABS Fuse/Relay Box Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Electrical Load Detector (ELD) Unit > Page 1634 Relay Box: Locations Under-Hood Fuse/Relay Box Photo Right Rear Corner Of Engine Compartment Under-Hood Fuse/Relay Box Fuse/Relay Information-Under-hood Fuse/Relay Box (Part 1 Of 2) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Electrical Load Detector (ELD) Unit > Page 1635 Fuse/Relay Information-Under-hood Fuse/Relay Box (Part 1 Of 2) Fuse/Relay Information-Under-hood Fuse/Relay Box (Part 2 Of 2) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Under-Dash Fuse/Relay Box Relay Box: Application and ID Under-Dash Fuse/Relay Box Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 1 Of 3) Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Under-Dash Fuse/Relay Box > Page 1638 Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 2 Of 3) Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 3 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Under-Dash Fuse/Relay Box > Page 1639 Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 3 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Under-Dash Fuse/Relay Box > Page 1640 Relay Box: Application and ID Under-Hood ABS Fuse/Relay Box Fuse/Relay Information-Under-hood ABS Fuse/Relay Box Fuse/Relay Information-Under-hood ABS Fuse/Relay Box Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Under-Dash Fuse/Relay Box > Page 1641 Relay Box: Application and ID Under-Hood Fuse/Relay Box Fuse/Relay Information-Under-hood Fuse/Relay Box (Part 1 Of 2) Fuse/Relay Information-Under-hood Fuse/Relay Box (Part 1 Of 2) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Under-Dash Fuse/Relay Box > Page 1642 Fuse/Relay Information-Under-hood Fuse/Relay Box (Part 2 Of 2) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator > Component Information > Service and Repair Maintenance Required Lamp/Indicator: Service and Repair If equipped with maintenance reminder flag: After completing the required service, the maintenance flags may be reset by inserting the ignition key into the appropriate slot, on the instrument below the indicator flag. When the ignition key is inserted into the slot, the indicator flag should change to green. If equipped with maintenance reminder lamp: 1. Turn off the engine. 2. Press and hold the select/reset button(s) on the instrument panel, then turn the ignition switch ON (Position II). 3. Hold the button(s) for at least 10 seconds, until the indicator resets. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Locations > Page 1650 Malfunction Indicator Lamp: Testing and Inspection When the Malfunction Indicator Lamp (MIL) has been reported on, do the following: 1. Connect the Service Check Connector terminals with a jumper wire as shown. (The 2P Service Check Connector is located under the dash on the passenger side of the car.) Turn the ignition switch on. 2. Note the Diagnostic Trouble Code (DTC): The MIL indicates a code by the length and number of blinks. The MIL can indicate simultaneous component problems by blinking separate codes, one after another. Codes I through 9 are indicated by individual short blinks. Codes 10 through 48 are indicated by a series of long and short blinks. The number of long blinks equals the first digit, the number of Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 94025 > Aug > 94 > Steering - Wheel Oscillates or Has a Shimmy Tires: Customer Interest Steering - Wheel Oscillates or Has a Shimmy Bulletin No. 94-025 Model ALL Applicable To ALL File Under SUSPENSION Issue Date AUG 22, 1994 Steering Wheel Shimmy SYMPTOM The steering wheel oscillates, or shimmies, when driving between 58 and 62 mph. It may be most noticeable on smooth roads, and may vary with slight steering inputs. PROBABLE CAUSE An imbalance of the wheel/tire/hub/disc assembly in the front end. CORRECTIVE ACTION Dynamically balance the wheel and tire assembly off the car. Then, if necessary, use the Hofmann Finish Wheel Balancer to balance the wheel/tire/hub/disc assembly on the car. 1. Drive the car on a smooth surface between 58 and 62 mph. Turn the steering wheel slightly, and allow the steering to self-center. Repeat this several times and observe the steering wheel motion. If the steering wheel does not oscillate, or the movement is different than shown below, the car does not have an imbalance problem. Do not continue with this procedure. If the steering wheel oscillates as shown, continue with this procedure. 2. Dynamically balance all four wheel/tire assemblies off the car. Make sure the balancer is capable of balancing to an accuracy of within 5 grams. Use only Honda wheel weights (see PARTS INFORMATION). NOTE: To verify the balancer's accuracy and calibration, refer to the DYNAMIC OFF-CAR WHEEL BALANCER CALIBRATION CHECK. 3. Reinstall the balanced wheel/tire assemblies and torque the wheel nuts to 80 lb.ft. Do not use an impact wrench to snug up or torque the wheel nuts; it may damage or distort the wheel and cause steering wheel oscillation. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 94025 > Aug > 94 > Steering - Wheel Oscillates or Has a Shimmy > Page 1660 4. Road test the car and check for steering wheel oscillation. If it still oscillates, use the Hofmann Finish Wheel Balancer to do a finish balance on the front wheel/tire/hub/disc assemblies. NOTE: Refer to section 4 of the Hofmann DAFB-10 Finish Wheel Balancer Operator's Manual that came with the unit for detailed instructions. DYNAMIC OFF-CAR WHEEL BALANCER CALIBRATION CHECK Use this procedure to determine if the balancer is accurate to within 5 grams of imbalance. If the balancer is not accurate to within 5 grams, it must be calibrated or repaired before being used to correct a steering wheel oscillation problem. You will need a Honda factory or accessory alloy wheel only, with no tire mounted, to perform this procedure. 1. Before starting, make sure the wheel has no balance weights. Perform a static balance, adding weights as necessary to only one side of the wheel. 2. Loosen the wheel, rotate it 901, tighten the wheel, and recheck the balance. Repeat this three more times, until the wheel returns to its original position. The balancer should not indicate any more than 5 grams of additional weight is needed during this procedure. If more than 5 grams is indicated, calibrate or repair the balancer. 3. Remove the weights just installed. Make sure the balancer is set to its finest balancing mode (accuracy within 5 grams). 4. Perform a dynamic balance, adding weights as indicated by the balancer to both sides of the wheel. 5. Once the wheel is in dynamic balance, add an additional 5 grams at any point on the rim and recheck the balance. The balancer should indicate that 5 grams is needed on the same side of the wheel at a point exactly opposite the weight you added. If so, the balancer is in calibration. If the balancer indicates that more than 10 grams is needed, or the indicated position is more than 1.5 inches from the point exactly opposite the weight you added, then the balancer needs calibration or repair. PARTS INFORMATION WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. Failed part: P/N 42700-SM1-A01 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 94025 > Aug > 94 > Steering - Wheel Oscillates or Has a Shimmy > Page 1661 H/C 3251550 Defect code: 045 Contention code: B99 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 06-082 > Dec > 06 > Tires - Tubless Tire Repair Information Tires: All Technical Service Bulletins Tires - Tubless Tire Repair Information 06-082 December 15, 2006 Applies To: ALL Tubeless Tire Repair Information This service bulletin provides the resource information required to repair tubeless tires on Honda automobiles and light trucks. To properly repair a tire, follow the Rubber Manufacturers Association (RMA) "Puncture Repair Procedures for Passenger and Light Truck Tires" outlined on the RMA wall poster. One wall poster has been provided to your dealership. Additional posters can be ordered through Helm, the RMA website, www.rma.org, or the tire manufacturers. Michelin(R) PAX System(TM), tires can be repaired using the same repair procedures described on the RMA poster. Whenever you repair a PAX System tire, you must inspect the support ring. Refer to the PAX System support ring section of this service bulletin for inspection procedures. WARRANTY CLAIM INFORMATION Refer to the tire manufacturer for warranty information. REQUIRED MATERIALS ^ 1/8 inch Patch-plug with lead wire ^ 1/4 inch Patch-plug with lead wire ^ 1/8 inch Plugs (stem)* ^ 1/4 inch Plugs (stem)* ^ 1/4 inch Patches* ^ 3/4 inch Patches* ^ Chemical cement ^ Liquid buffer ^ Rim-bead sealer ^ Inner liner sealer REQUIRED TOOLS ^ Tire stitcher, 1-1/2 inch wheel ^ Tire crayons ^ Tire test tank ^ Awl or probe ^ Flexible blade skiving knife ^ 1/8 inch Carbide tire tool with adapter ^ 1/4 inch Carbide tire tool with adapter ^ Low speed buffer with quick release chuck and exhaust hose ^ Carbide buffing wheel with adapter Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 06-082 > Dec > 06 > Tires - Tubless Tire Repair Information > Page 1667 ^ Reversible drill motor (800 RPM MAX) ^ Tire spreader ^ Inspection lamp * For repairable injuries that exceed 25 degrees TIRE REPAIR GUIDELINES Never repair tires worn below 2/32 inch of tread. Never repair a tire without removing the tire from the wheel for internal inspection. Never repair a tire with a tread injury larger than 1/4 inch (6 mm). Never use only a plug (stem) or a patch only to repair a tire injury. NOTE: If the angle of the tire injury exceeds 25 degrees, you must use the two-piece repair system as recommended by the RMA. MICHELIN PAX SYSTEM SUPPORT RING INSPECTION PAX System support rings are not repairable, under any circumstances, but they can be reused if no damage is found during a thorough inspection. If a PAX System tire ran flat or underinflated, dismount the tire from the wheel and inspect the wheel, tire, and support ring for damage. Refer to the Michelin PAX Support Rings Technical Bulletin in ISIS. Enter SEARCH BY PUBLICATION, select Job Aids, then select Michelin PAX Support Rings Technical Bulletin from the list. Disclaimer Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 94025 > Aug > 94 > Steering - Wheel Oscillates or Has a Shimmy Tires: All Technical Service Bulletins Steering - Wheel Oscillates or Has a Shimmy Bulletin No. 94-025 Model ALL Applicable To ALL File Under SUSPENSION Issue Date AUG 22, 1994 Steering Wheel Shimmy SYMPTOM The steering wheel oscillates, or shimmies, when driving between 58 and 62 mph. It may be most noticeable on smooth roads, and may vary with slight steering inputs. PROBABLE CAUSE An imbalance of the wheel/tire/hub/disc assembly in the front end. CORRECTIVE ACTION Dynamically balance the wheel and tire assembly off the car. Then, if necessary, use the Hofmann Finish Wheel Balancer to balance the wheel/tire/hub/disc assembly on the car. 1. Drive the car on a smooth surface between 58 and 62 mph. Turn the steering wheel slightly, and allow the steering to self-center. Repeat this several times and observe the steering wheel motion. If the steering wheel does not oscillate, or the movement is different than shown below, the car does not have an imbalance problem. Do not continue with this procedure. If the steering wheel oscillates as shown, continue with this procedure. 2. Dynamically balance all four wheel/tire assemblies off the car. Make sure the balancer is capable of balancing to an accuracy of within 5 grams. Use only Honda wheel weights (see PARTS INFORMATION). NOTE: To verify the balancer's accuracy and calibration, refer to the DYNAMIC OFF-CAR WHEEL BALANCER CALIBRATION CHECK. 3. Reinstall the balanced wheel/tire assemblies and torque the wheel nuts to 80 lb.ft. Do not use an impact wrench to snug up or torque the wheel nuts; it may damage or distort the wheel and cause steering wheel oscillation. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 94025 > Aug > 94 > Steering - Wheel Oscillates or Has a Shimmy > Page 1672 4. Road test the car and check for steering wheel oscillation. If it still oscillates, use the Hofmann Finish Wheel Balancer to do a finish balance on the front wheel/tire/hub/disc assemblies. NOTE: Refer to section 4 of the Hofmann DAFB-10 Finish Wheel Balancer Operator's Manual that came with the unit for detailed instructions. DYNAMIC OFF-CAR WHEEL BALANCER CALIBRATION CHECK Use this procedure to determine if the balancer is accurate to within 5 grams of imbalance. If the balancer is not accurate to within 5 grams, it must be calibrated or repaired before being used to correct a steering wheel oscillation problem. You will need a Honda factory or accessory alloy wheel only, with no tire mounted, to perform this procedure. 1. Before starting, make sure the wheel has no balance weights. Perform a static balance, adding weights as necessary to only one side of the wheel. 2. Loosen the wheel, rotate it 901, tighten the wheel, and recheck the balance. Repeat this three more times, until the wheel returns to its original position. The balancer should not indicate any more than 5 grams of additional weight is needed during this procedure. If more than 5 grams is indicated, calibrate or repair the balancer. 3. Remove the weights just installed. Make sure the balancer is set to its finest balancing mode (accuracy within 5 grams). 4. Perform a dynamic balance, adding weights as indicated by the balancer to both sides of the wheel. 5. Once the wheel is in dynamic balance, add an additional 5 grams at any point on the rim and recheck the balance. The balancer should indicate that 5 grams is needed on the same side of the wheel at a point exactly opposite the weight you added. If so, the balancer is in calibration. If the balancer indicates that more than 10 grams is needed, or the indicated position is more than 1.5 inches from the point exactly opposite the weight you added, then the balancer needs calibration or repair. PARTS INFORMATION WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. Failed part: P/N 42700-SM1-A01 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 94025 > Aug > 94 > Steering - Wheel Oscillates or Has a Shimmy > Page 1673 H/C 3251550 Defect code: 045 Contention code: B99 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 06-082 > Dec > 06 > Tires - Tubless Tire Repair Information Tires: All Technical Service Bulletins Tires - Tubless Tire Repair Information 06-082 December 15, 2006 Applies To: ALL Tubeless Tire Repair Information This service bulletin provides the resource information required to repair tubeless tires on Honda automobiles and light trucks. To properly repair a tire, follow the Rubber Manufacturers Association (RMA) "Puncture Repair Procedures for Passenger and Light Truck Tires" outlined on the RMA wall poster. One wall poster has been provided to your dealership. Additional posters can be ordered through Helm, the RMA website, www.rma.org, or the tire manufacturers. Michelin(R) PAX System(TM), tires can be repaired using the same repair procedures described on the RMA poster. Whenever you repair a PAX System tire, you must inspect the support ring. Refer to the PAX System support ring section of this service bulletin for inspection procedures. WARRANTY CLAIM INFORMATION Refer to the tire manufacturer for warranty information. REQUIRED MATERIALS ^ 1/8 inch Patch-plug with lead wire ^ 1/4 inch Patch-plug with lead wire ^ 1/8 inch Plugs (stem)* ^ 1/4 inch Plugs (stem)* ^ 1/4 inch Patches* ^ 3/4 inch Patches* ^ Chemical cement ^ Liquid buffer ^ Rim-bead sealer ^ Inner liner sealer REQUIRED TOOLS ^ Tire stitcher, 1-1/2 inch wheel ^ Tire crayons ^ Tire test tank ^ Awl or probe ^ Flexible blade skiving knife ^ 1/8 inch Carbide tire tool with adapter ^ 1/4 inch Carbide tire tool with adapter ^ Low speed buffer with quick release chuck and exhaust hose ^ Carbide buffing wheel with adapter Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 06-082 > Dec > 06 > Tires - Tubless Tire Repair Information > Page 1679 ^ Reversible drill motor (800 RPM MAX) ^ Tire spreader ^ Inspection lamp * For repairable injuries that exceed 25 degrees TIRE REPAIR GUIDELINES Never repair tires worn below 2/32 inch of tread. Never repair a tire without removing the tire from the wheel for internal inspection. Never repair a tire with a tread injury larger than 1/4 inch (6 mm). Never use only a plug (stem) or a patch only to repair a tire injury. NOTE: If the angle of the tire injury exceeds 25 degrees, you must use the two-piece repair system as recommended by the RMA. MICHELIN PAX SYSTEM SUPPORT RING INSPECTION PAX System support rings are not repairable, under any circumstances, but they can be reused if no damage is found during a thorough inspection. If a PAX System tire ran flat or underinflated, dismount the tire from the wheel and inspect the wheel, tire, and support ring for damage. Refer to the Michelin PAX Support Rings Technical Bulletin in ISIS. Enter SEARCH BY PUBLICATION, select Job Aids, then select Michelin PAX Support Rings Technical Bulletin from the list. Disclaimer Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service Precautions > Technician Safety Information Tires: Technician Safety Information WARNING: This vehicle has a Supplemental Restraint System (SRS). Refer to the SRS component and wiring location view in order to determine whether you are performing service on or near the SRS components or the SRS wiring. when you are performing service on or near the SRS components or the SRS wiring, refer to the SRS service information. failure to follow warnings could result in possible air bag deployment, personal injury, or otherwise unneeded SRS system repairs. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service Precautions > Technician Safety Information > Page 1682 Tires: Vehicle Damage Warnings CAUTION: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. Honda will call out those fasteners that require a replacement after removal. Honda will also call out the fasteners that require thread lockers or thread sealant. Unless otherwise specified, do not use supplemental coatings (Paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and the joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service Precautions > Page 1683 Tires: Description and Operation GENERAL DESCRIPTION Replacement wheels or tires must be equivalent to the originals in load capacity, specified dimension and mounting configuration. Improper size or type may affect bearing life, brake performance, speedometer/odometer calibration, vehicle ground clearance and tire clearance to the body and chassis. All model are equipped with metric sized tubeless steel belted radial tires. Correct tire pressures and driving habits have an important influence on tire life. Heavy cornering, excessively rapid acceleration and unnecessary sharp braking increase premature and uneven wear. TREAD WEAR INDICATORS The original equipment tires have built-in tread wear indicators (1) to show when tires need replacement. These indicators may appear as wide bands. When the indicators appear in two or more grooves at three locations, tire replacement is recommended. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Testing and Inspection > Abnormal Tire Ahead Wear and Major Causes Tires: Testing and Inspection Abnormal Tire Ahead Wear and Major Causes TYPICAL EXAMPLES OF ABNORMAL TIRE AHEAD WEAR AND MAJOR CAUSES: CAUTION: Similar wear patterns can be caused by worn suspension parts, misalignment of wheels and tires, and other suspension related problems. Spotty Wear Wear localized on shoulder sections, and in an extreme cases, the tire becomes polygonal in shape. 1. Tire or wheel out of round or distorted. 2. Hub or knuckle out of round or distorted. 3. Play in hub bearings or ball joint. 4. Rotating parts out of balance. Tread Wear One-Sided 1. Rotating parts out of balance. 2. Tire or wheel out of round. 3. Hub or knuckle out of round or distorted. Localized Tread Wear Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Testing and Inspection > Abnormal Tire Ahead Wear and Major Causes > Page 1686 1. Once spotty wear develops in tread due to hard braking or abrupt starting, localized wear tends to be promoted. Shoulder Wear (Generally Wear Develops In Outer Shoulder): 1. Camber or toe-in incorrect. 2. Shoulder wear caused by repeated hard-cornering. Wear In Shoulders At Points Opposed To Each Other 1. Tire or wheel out of round or distorted. 2. Play in bearings or ball joint. Premature Wear In Shoulders 1. Flexing of tire excessive due to under-inflation. One Sided Feather Edging 1. Wear caused by repeated hard cornering. 2. Camber or toe-in incorrect. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Testing and Inspection > Abnormal Tire Ahead Wear and Major Causes > Page 1687 Tires: Testing and Inspection Diagnosis By Symptom Part 1 Of 2 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Testing and Inspection > Abnormal Tire Ahead Wear and Major Causes > Page 1688 Part 2 Of 2 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Testing and Inspection > Abnormal Tire Ahead Wear and Major Causes > Page 1689 Tires: Testing and Inspection Diagnosis List If the following conditions are noted, rotation is required. 1. Front tire wear is different from rear. 2. Uneven wear exists across the tread of any tire. 3. Left and right front tire wear is unequal. 4. Left and right rear tire wear is unequal. If the following conditions are noted, check the wheel alignment. 1. Left and right front tire wear is unequal. 2. Uneven wear exists across the tread of any tire. 3. Front tire treads have scuffed appearance with "feather" edges on one side of tread ribs or blocks. 4. There is cupping, flat spotting etc. Higher than recommended pressure can cause: 1. Hard ride. 2. Poor steering stability. 3. Rapid and uneven wear at center of the tread. Lower than recommended pressure can cause: 1. Tire squeal on turns. 2. Hard steering. 3. Rapid and uneven wear on the edges of the tread. 4. Tire rim bruises and rupture. 5. Tire cord breakage. 6. High tire temperatures. 7. Reduced handling. 8. Reduced fuel economy. Unequal pressure on same axle can cause: 1. Uneven braking. 2. Steering lead. 3. Reduced handling. 4. Swerve on acceleration. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Testing and Inspection > Abnormal Tire Ahead Wear and Major Causes > Page 1690 Tires: Testing and Inspection Irregular and Premature Wear Irregular and/or premature wear has many causes. Some of them are incorrect inflation pressures, lack of tire rotation, poor driving habits or improper wheel alignment. Incorrect inflation is common cause of tire premature wear. NOTE: Due to their design, radial tires tend to wear faster in the shoulder area, particularly on the front tires. This makes regular rotation especially necessary. After rotation, be sure to check wheel nut torque, and set tire pressures. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Testing and Inspection > Abnormal Tire Ahead Wear and Major Causes > Page 1691 Tires: Testing and Inspection Abnormal Tire Ahead Wear and Major Causes TYPICAL EXAMPLES OF ABNORMAL TIRE AHEAD WEAR AND MAJOR CAUSES: CAUTION: Similar wear patterns can be caused by worn suspension parts, misalignment of wheels and tires, and other suspension related problems. Spotty Wear Wear localized on shoulder sections, and in an extreme cases, the tire becomes polygonal in shape. 1. Tire or wheel out of round or distorted. 2. Hub or knuckle out of round or distorted. 3. Play in hub bearings or ball joint. 4. Rotating parts out of balance. Tread Wear One-Sided 1. Rotating parts out of balance. 2. Tire or wheel out of round. 3. Hub or knuckle out of round or distorted. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Testing and Inspection > Abnormal Tire Ahead Wear and Major Causes > Page 1692 Localized Tread Wear 1. Once spotty wear develops in tread due to hard braking or abrupt starting, localized wear tends to be promoted. Shoulder Wear (Generally Wear Develops In Outer Shoulder): 1. Camber or toe-in incorrect. 2. Shoulder wear caused by repeated hard-cornering. Wear In Shoulders At Points Opposed To Each Other 1. Tire or wheel out of round or distorted. 2. Play in bearings or ball joint. Premature Wear In Shoulders 1. Flexing of tire excessive due to under-inflation. One Sided Feather Edging 1. Wear caused by repeated hard cornering. 2. Camber or toe-in incorrect. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Testing and Inspection > Abnormal Tire Ahead Wear and Major Causes > Page 1693 Part 1 Of 2 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Testing and Inspection > Abnormal Tire Ahead Wear and Major Causes > Page 1694 Part 2 Of 2 Diagnosis List If the following conditions are noted, rotation is required. 1. Front tire wear is different from rear. 2. Uneven wear exists across the tread of any tire. 3. Left and right front tire wear is unequal. 4. Left and right rear tire wear is unequal. If the following conditions are noted, check the wheel alignment. 1. Left and right front tire wear is unequal. 2. Uneven wear exists across the tread of any tire. 3. Front tire treads have scuffed appearance with "feather" edges on one side of tread ribs or blocks. 4. There is cupping, flat spotting etc. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Testing and Inspection > Abnormal Tire Ahead Wear and Major Causes > Page 1695 Higher than recommended pressure can cause: 1. Hard ride. 2. Poor steering stability. 3. Rapid and uneven wear at center of the tread. Lower than recommended pressure can cause: 1. Tire squeal on turns. 2. Hard steering. 3. Rapid and uneven wear on the edges of the tread. 4. Tire rim bruises and rupture. 5. Tire cord breakage. 6. High tire temperatures. 7. Reduced handling. 8. Reduced fuel economy. Unequal pressure on same axle can cause: 1. Uneven braking. 2. Steering lead. 3. Reduced handling. 4. Swerve on acceleration. Irregular and Premature Wear Irregular and/or premature wear has many causes. Some of them are incorrect inflation pressures, lack of tire rotation, poor driving habits or improper wheel alignment. Incorrect inflation is common cause of tire premature wear. NOTE: Due to their design, radial tires tend to wear faster in the shoulder area, particularly on the front tires. This makes regular rotation especially necessary. After rotation, be sure to check wheel nut torque, and set tire pressures. Radial Tire Lead/Pull "Lead/Pull" is vehicle deviation from a straight path, on a level road with no pressure on the steering wheel. Lead is usually caused by: 1. Poorly manufactured radial tires. 2. Uneven brake adjustment. 3. Wheel alignment. The way in which a tire is built can produce lead in a car. An example of this is placement of the belt. Off-center belts on radial tires can cause the tire to develop a side force while rolling straight down the road and the tire will tend to roll like a cone. The "Radial Tire Lead/Pull Correction" chart should be used to make sure that front wheel alignment is not mistaken for tire lead. Rear tires will not cause lead/pull. Radial Tire Waddle Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Testing and Inspection > Abnormal Tire Ahead Wear and Major Causes > Page 1696 Waddle is side-to-side movement at the front and/or rear of the car. It can be caused by the steel belt not being straight within the tire, or by excessive lateral runout of the tire or wheel. It is most noticeable at low speed, about 8 to 48 km/h (5 to 30 mph). It may also cause rough ride at 80 to 113 km/h (50 to 70 mph). The car can be road tested to see which end of the car has the faulty tire. If the tire causing the waddle is on the rear, the rear end of the car will "waddle". From the driver's seat, it feels as if someone is pushing on the side of the car. If the faulty tire is on the front, the waddle is more easily seen. The front sheet metal appears to be moving back and forth. It feels as if the driver's seat is the pivot point in the car. Another more time-consuming method of determining the faulty tire is substituting tire and wheel assemblies that are known to be good. Follow these steps: 1. Drive the car to determine if the waddle is coming from the front or rear. 2. Install tire and wheel assemblies known to be good (from a similar car) in place of those on the end of the car which is waddling. If the waddle cannot be isolated to front or rear, start with the rear tires. 3. Road test again. If improvement is noted, install the original tire and wheel assemblies one at a time until the faulty tire is found. If no improvement is noted, install tires known to be good in place of all four. Then, install the originals one at a time until the faulty tire is found. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Separating the Tire From the Wheel Tires: Service and Repair Separating the Tire From the Wheel Use a tire changing machine to demount tires. Do not use hand tools or tire irons alone to remove the tire from the wheel. Damage to the tire beads or wheel rim could result. Follow the tire changing machine manufacturer's instructions to properly separate the tire from the wheel. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Separating the Tire From the Wheel > Page 1699 Tires: Service and Repair Mounting the Tire on the Wheel CAUTION: Recommended vehicle tire mounting and inflation procedures are especially important with radial tires. Failure to follow these procedures can cause bead deformation in both tube type and tubeless tires due to incorrect bead seating. Bead deformation may lead to chafing, lower sidewall and bead area cracking, eccentric wear, ride vibration and nonretreadable casings. Only use rims approved for radial tire usage by the rim manufacture. 1. Clean the rim. Remove all rust and other foreign material. 2. Lubricate tire beads and rim bead seats with an approved rubber lubricant. CAUTION: Do not use silicon base lubricants. This could cause the tire to slip on the wheel. 3. Attach the tire to the wheel. a. Use a tire changing machine. b. Align air valve and tire balancing match marks (about 8 mm diameter paint mark). Hold in this position and inflate the until the tire beads are firmly seated on the rim against the flanges (steel wheel model only). 4. Inflate the tire to operating pressure. 5. Check the bead seating. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Separating the Tire From the Wheel > Page 1700 Tires: Service and Repair Balancing Deposits of mud, etc. must be cleaned from the inside of the rim. The tire should be inspected for the following: match mount paint marks, bent rims, bulges, irregular tire wear, proper wheel size and inflation pressure. Then balance according to the equipment manufacturer's recommendations. There are two types of wheel and tire balance: a. Static balance is the equal distribution of weight around the wheel. Assemblies that are statically unbalanced cause a bouncing action called tramp. This condition will eventually cause uneven tire wear. b. Dynamic balance is the equal distribution of weight on each side of the wheel center-line so that when the tire spins there is no tendency for the assembly to move from side to side. Assemblies that are dynamically unbalanced may cause shimmy. WARNING: Stones should be removed from the tread to avoid operator injury during spin balancing and to obtain a good balance. NOTE: Using wheel balancing equipment. Follow the tire balancing machine manufacturer's instructions to properly balance wheel and tire. Balance weight for the wheel should not exceed 170 g in total, and 140 g is the maximum amount for either side. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Separating the Tire From the Wheel > Page 1701 Tires: Service and Repair Tire Rotation Tire rotation is recommended to equalize wear for longer life. If the following conditions are noted, rotate the tires: - Front tire wear is different from rear. - Uneven wear exists across the tread of any tire. - Left and right front tire wear is unequal. - Left and right rear tire wear is unequal. Check wheel alignment if the following conditions are noted: - Left and right front tire wear is unequal. - Wear is uneven across the tread of any front tire. - Front tire treads have a scuffed appearance with "feather" edges on one side of the tread ribs or blocks. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Separating the Tire From the Wheel > Page 1702 Tires: Service and Repair Separating the Tire From the Wheel Use a tire changing machine to demount tires. Do not use hand tools or tire irons alone to remove the tire from the wheel. Damage to the tire beads or wheel rim could result. Follow the tire changing machine manufacturer's instructions to properly separate the tire from the wheel. Mounting the Tire on the Wheel CAUTION: Recommended vehicle tire mounting and inflation procedures are especially important with radial tires. Failure to follow these procedures can cause bead deformation in both tube type and tubeless tires due to incorrect bead seating. Bead deformation may lead to chafing, lower sidewall and bead area cracking, eccentric wear, ride vibration and nonretreadable casings. Only use rims approved for radial tire usage by the rim manufacture. 1. Clean the rim. Remove all rust and other foreign material. 2. Lubricate tire beads and rim bead seats with an approved rubber lubricant. CAUTION: Do not use silicon base lubricants. This could cause the tire to slip on the wheel. 3. Attach the tire to the wheel. a. Use a tire changing machine. b. Align air valve and tire balancing match marks (about 8 mm diameter paint mark). Hold in this position and inflate the until the tire beads are firmly seated on the rim against the flanges (steel wheel model only). 4. Inflate the tire to operating pressure. 5. Check the bead seating. Balancing Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Separating the Tire From the Wheel > Page 1703 Deposits of mud, etc. must be cleaned from the inside of the rim. The tire should be inspected for the following: match mount paint marks, bent rims, bulges, irregular tire wear, proper wheel size and inflation pressure. Then balance according to the equipment manufacturer's recommendations. There are two types of wheel and tire balance: a. Static balance is the equal distribution of weight around the wheel. Assemblies that are statically unbalanced cause a bouncing action called tramp. This condition will eventually cause uneven tire wear. b. Dynamic balance is the equal distribution of weight on each side of the wheel center-line so that when the tire spins there is no tendency for the assembly to move from side to side. Assemblies that are dynamically unbalanced may cause shimmy. WARNING: Stones should be removed from the tread to avoid operator injury during spin balancing and to obtain a good balance. NOTE: Using wheel balancing equipment. Follow the tire balancing machine manufacturer's instructions to properly balance wheel and tire. Balance weight for the wheel should not exceed 170 g in total, and 140 g is the maximum amount for either side. Tire Rotation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Separating the Tire From the Wheel > Page 1704 Tire rotation is recommended to equalize wear for longer life. If the following conditions are noted, rotate the tires: - Front tire wear is different from rear. - Uneven wear exists across the tread of any tire. - Left and right front tire wear is unequal. - Left and right rear tire wear is unequal. Check wheel alignment if the following conditions are noted: - Left and right front tire wear is unequal. - Wear is uneven across the tread of any front tire. - Front tire treads have a scuffed appearance with "feather" edges on one side of the tread ribs or blocks. Inflation of Tires Tire pressure, in cold condition (after vehicle has set for three hours or more, and driven less than one mile) should be checked monthly or before any extended trip. Tire pressure increases approximately 15% when the tires become hot during driving. Tire pressure specification is shown on the label located on the left door lock pillar. NOTE: Check the tire pressure whenever irregular wear is found. Tire inflation greatly affects tire wear. If the alignment check does not reveal any alignment problems, check the condition of the shock absorbers and wheel/tire balance. Tire Replacement TIRE REPLACEMENT When replacement is necessary, the original metric the size should be used. Most metric tire sizes do not have exact corresponding alphanumeric tire sizes. It is recommended that new tires be installed in pairs on the same axle. If necessary to replace only one tire, it should be paired with tire having the most tread, to equalize braking traction. CAUTION: Do not mix different types of tires such as radial, bias and bias-belted tires except in emergencies, because vehicle handling may be seriously affected and may result in loss of control. Tire Dismounting Remove valve cap on valve step and deflate the tire. Then use a tire changing machine to mount or dismount tires. Follow the equipment manufacturer's instruction. Do not use hand tools or tire lever alone to change tires as they may damage the tire beads or wheel rim. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Separating the Tire From the Wheel > Page 1705 Tire Mounting Rim bead seats should be cleaned with a wire brush or coarse steel wool to remove lubricants, and light rust. Before mounting a tire, the bead area should be well lubricated with an approved tire lubricant. After mounting, inflate the tire to 196 kPa (28 psi) so that beads are completely seated. Inflate the air to specified pressure and install valve cap to the stem. WARNING: Never stand over tire when inflating. bead may break when bead snaps over rim's safety hump and cause serious personal injury. never exceed 240 kPa (35 psi) pressure when inflating. if 240 kPa (35 psi) pressure will not seat beads, deflate, re-lubricate and re-inflate. over inflation may cause the bead to break and cause serious personal injury. Tire Repair There are many different materials on the market used to repair tires. Manufacturers have published detailed instructions on how and when to repair tires. These instructions can be obtained from the tire manufacturer if they are not included with the repair kit. Wheel Inspection Damaged wheels and wheels with excessive run-out must be replaced. Wheel run out at rim (Base on hub Bore): General Balance Procedure Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Separating the Tire From the Wheel > Page 1706 Deposits of mud, etc. must be cleaned from the inside of the rim. The tire should be inspected for the following: match mount paint marks, bent rims, bulges, irregular tire wear, proper wheel size and inflation pressure. Then balance according to the equipment manufacturer's recommendations. There are two types of wheel and tire balance. Static balance is the equal distribution of weight around the wheel. Assemblies that are statically unbalanced cause a bouncing action called tramp. This condition will eventually cause uneven tire wear. Dynamic balance is the equal distribution of weight on each side of the wheel center-line so that when the tire spins there is no tendency for the assembly to move from side to side. Assemblies that are dynamically unbalanced may cause shimmy. WARNING: Stones should be removed from the tread to avoid operator injury during spin balancing and to obtain a good balance. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Adjustments Wheel Bearing: Adjustments Wheel bearings and hub on these models are an integral assembly and bearings cannot be adjusted. If hub endplay exceeds 0.002 inch with spindle nut properly tightened, hub and bearing assembly should be replaced. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension Wheel Bearing: Service and Repair Front Suspension 1. Raise and support front of vehicle, then remove front wheels. 2. Raise spindle nut locking tab, then remove spindle nut. 3. Remove brake hose bracket mounting bolts. 4. Remove caliper and position aside. Do not allow caliper assembly to hang from brake hose. 5. Remove brake disc attaching screws, then thread two 8 x 1.25 x 12 mm bolts into attaching screw holes to push disc from hub. When tightening screws, turn only two turns at a time to prevent excessively cocking the brake disc. 6. Remove brake disc from knuckle. 7. Remove speed sensor wire bracket, then the speed sensor from knuckle. 8. Remove tie rod end cotter pin and nut. 9. Remove tie rod end using suitable tie rod end remover. 10. Remove lower ball joint cotter pin, then loosen ball joint nut half way. 11. Using ball joint remover tool No. 07MAC-SL00200, or equivalent, separate ball joint and lower arm. 12. Remove upper ball joint shield, then the cotter pin and nut. 13. Separate upper ball joint from upper arm using suitable ball joint remover. 14. Remove steering knuckle and hub assembly by sliding off driveshaft. 15. Remove hub from steering knuckle using suitable press. 16. Remove knuckle ring, circlip and splash guard from knuckle. 17. Press out wheel bearing from hub using driver tool No. 07749-0010000, attachment tool No. 07746-0010500 and base tool No. 07GAF-SE00401, or equivalents. 18. Remove outboard bearing inner race from hub. Fig. 4 Front Suspension 19. Reverse procedure to install. Refer to Fig. 2 for tightening specifications. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 1712 Wheel Bearing: Service and Repair Rear Suspension Disc Brake Models 1. Raise and support vehicle, then remove rear wheels. 2. Apply parking brake, then remove hub cap. 3. Raise locking tab on spindle nut, then remove nut. 4. Remove 6 mm brake disc retaining screw, then the caliper shield. 5. Remove brake hose mounting bolts, then the caliper bracket mounting bolts. 6. Remove caliper and hang from undercarriage with short piece of wire. Do not hang caliper by brake hose. 7. Screw two 12 mm bolts into disc to push disc off of hub. Remove disc. 8. Remove hub unit from knuckle. 9. Reverse procedure to install. Drum Brake Models 1. Raise and support rear of vehicle, then remove wheel and brake drum. 2. Remove grease cap, spindle nut and washer. 3. Remove hub and bearing unit from spindle. 4. Reverse procedure to install. Tighten spindle nut to specifications, then stake shoulder of nut into groove in spindle. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Component .......................................................................................................................................... .......................................................... Torque/Ft. Lbs. Spindle Nut ...................................................... .............................................................................................................................................................. .. 134 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications TIGHTENING SPECIFICATIONS Wheel Nut ............................................................................................................................................ ................................................... 110 Nm (80 ft. lbs.) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions Variable Valve Timing Actuator: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1727 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1728 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1729 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1730 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1731 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1732 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1733 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1734 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1735 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1736 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1737 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1738 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1739 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1740 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1741 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1742 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1743 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1744 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1745 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1746 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1747 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1748 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1749 Variable Valve Timing Actuator: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1750 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1751 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1752 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1753 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1754 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1755 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1756 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1757 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1758 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1759 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1760 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1761 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1762 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1763 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1764 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1765 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1766 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1767 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1768 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1769 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1770 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1771 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1772 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1773 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1774 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1775 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications Check compression with engine at normal operating temperature and throttle in wide open position. Prior to performing test, disable ignition and fuel injection to prevent fuel from being sprayed into cylinders while cranking engine. Ensure is fully charged and that cranking speed is 250 RPM. Standard reading should be 135-184 psi. The maximum variation between cylinders is 28 psi. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Camshaft Pulley Bolt 27 ft.lb Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications Camshaft: Specifications Maximum Journal Run-out 0.001 in Camshaft Bearing Clearance 0.002-0.004 in Camshaft End Play 0.002-0.006 in Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 1786 Camshaft: Service and Repair 1. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. 2. Remove camshaft driven sprocket as described under Timing Belt. 3. Remove rocker arm assembly. 4. Carefully lift camshaft assembly from engine. 5. Reverse procedure to install, noting the following: a. Lubricate camshaft assembly prior to installation. b. Tighten each bearing cap bolt two turns at a time in a criss-cross fashion starting with center two caps and working outward, tighten to specification. c. After camshaft and rocker arms are installed, install new camshaft seal with spring side (open side) facing in, using suitable seal installation tool. d. Adjust timing belt. Refer to Timing Belt. 6. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Specifications Lifter / Lash Adjuster: Specifications Maximum Journal Runout .................................................................................................................... .............................................................. 0.001 inches Camshaft Bearing Clearance .......................... .......................................................................................................................................... 0.002-0.004 inches Camshaft Endplay ................................................................................................ .................................................................................... 0.002-0.006 inches Rocker Arm Oil Clearance ............................................................................................................................................ ..................................... 0.003 inches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications Rocker Arm Assembly: Specifications ROCKER ARM AND SHAFT TORQUE AND SEQUENCE Cam Holder Torque Sequence Tighten each bolt two turns at a time in the sequence shown to ensure that the rockers do not bind on the valves. SPECIFIED TORQUE: 8mm bolts: 22 Nm (2.2 kg-m, 16 lb.ft.) 6mm bolts: 12 Nm (1.2 kg-m, 9 lb.ft.) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications > Page 1793 Rocker Arm Assembly: Service and Repair Fig. 25 Exploded View Of Rocker Arm Assembly Disassemble one or all parts of rocker arm assembly as necessary, Fig. 25. Prior to removal, identify all parts so they can be installed in their original locations. When removing or installing rocker arm assembly, do not remove camshaft holder bolts. The bolts will keep the holders, springs and rocker arms on the shaft. When reassembling, fit the projection on the intake rocker shaft to the notch in the camshaft holder. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions Variable Valve Timing Actuator: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1798 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1799 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1800 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1801 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1802 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1803 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1804 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1805 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1806 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1807 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1808 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1809 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1810 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1811 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1812 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1813 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1814 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1815 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1816 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1817 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1818 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1819 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1820 Variable Valve Timing Actuator: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1821 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1822 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1823 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1824 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1825 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1826 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1827 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1828 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1829 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1830 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1831 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1832 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1833 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1834 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1835 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1836 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1837 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1838 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1839 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1840 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1841 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1842 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1843 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1844 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1845 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1846 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Service and Repair Connecting Rod Bearing: Service and Repair Rod and main bearings are available in several oversizes and undersizes and are identified by the color code on the edge of the bearing. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Technical Service Bulletins > Engine - Connecting Rod Damage Information Connecting Rod: Technical Service Bulletins Engine - Connecting Rod Damage Information Why Do Connecting Rods Break? Curious why connecting rods break? Afier all, these are heavy-duty parts specifically designed to endure punishing forces and temperatures. Yet, every once in a while they do bend or break and wind up as cool conversation pieces for a coffee table or desk. Connecting rods break only after they've gotten bent. And they won't get bent unless the engine hydro-locks or the rod bearings fail. When troubleshooting a bent or broken connecting rod, here are some things to consider: ^ The number one culprit for connecting rod breakage is hydro-lock. This happens when liquid (water or fuel) entering the combustion chamber exceeds the chamber's volume. Since liquids don't compress, that extra volume in the chamber causes the rod to bend. You won't really notice anything wrong, until that bent rod finally gives out and breaks. This could happen if you're driving through deep, standing water and someone coming the other way splashes water over your hood. On very rare occasions, a bad ECM/PCM or fuel injector can cause too much fuel to enter a cylinder, causing hydro-lock and resulting in a bent rod. Before this happens, though, there are usually some kind of drive ability problems that crop up and remain afier the engine is fixed. A bent rod might not show any symptoms until it actually breaks. But bent rods leave a wider-than-normal carbon witness line in the cylinder because they're shorter. Typically, a healthy engine has a carbon line that's 6 mm deep. An engine that's suffering from bent rods has a second carbon line that's 9 to 12 mm deep. ^ Connecting rod bearings fail for a number of reasons. To properly determine what actually caused a rod bearing to fail, you've got to take apart all rod bearings and main bearings and compare them side by side. If all or most of the bearings and journals show similar damage (scoring, exposed copper, or heat discoloration) the likely cause is oil starvation, poor maintenance, customer abuse, or running the engine with an aftermarket power booster (nitrous oxide setup, supercharger, turbocharger). If only the bearing or journal for the failed rod looks bad but all the other ones look good (no scoring, no exposed copper or heat discoloration) and the crankshaft journals are smooth with no heat discoloration, then that particular bearing/ clearance would be suspect. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Torque Specifications Connecting Rod: Specifications Torque Specifications Connecting Rod Bolt ............................................................................................................................ ....................................................... 32 Nm (23 lb ft) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Torque Specifications > Page 1857 Connecting Rod: Specifications Connecting Rods (Lower) Bore Diameter 1.7717 in 93honrep-033 Side Clearance 0.006-0.012 in Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 1858 Connecting Rod: Testing and Inspection SELECTION Each rod is sorted into one of four tolerance ranges (from 0 to + 0.024 mm (0 to + 0.0009 inch), in 0.006 mm (0.0002 inch) increments) depending on the size of its big end bore. It's then stamped with a number (1, 2, 3, or 4) indicating the range. You may find any combination of 1, 2, 3, or 4 in any engine. Normal Bore Size: 45.0 mm (1.77 inch) NOTE: Reference numbers are for big end bore size and do NOT indicate the position of the rod in the engine. - Inspect connecting rod for cracks and heat damage. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 1859 Connecting Rod: Service and Repair Fig. 57 Piston & Connecting Rod Assembly Install piston to rod as shown, Fig. 57. Pistons are available in standard and oversizes of 0.010 and 0.020 inches. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Service and Repair Crankshaft Main Bearing: Service and Repair Rod and main bearings are available in several oversizes and undersizes and are identified by the color code on the edge of the bearing. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications Crankshaft: Specifications Standard Journal Diameter: Main Bearing ....................................................................................................................................... ...................................... 1.7707-1.7717 inches Rod Journal Diameter ............................................... ................................................................................................................. 1.6526-1.6535 inches Out of Round Maximum ....................................................................................................................... ............................................................... 0.0001 inch Taper Maximum ............................................... ................................................................................................................................................... 0.0001 inch End Play ........................................................................................................................... ........................................................................ 0.004-0.014 inches Total Runout, Maximum .............. .............................................................................................................................................................. ........... 0.001 inch Bearing Clearance: Main Bearings ...................................................................................................................................... ................................................................. [01] Connecting Rod Bearings .......................................................................................................................................................... 0.0008-0.0015 inches [01] -- Nos. 1 & 5 journals, 0.0007-0.0014 inches; Nos. 2, 3 and 4 journals, 0.0009-0.0017 inches. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Removal Crankshaft: Service and Repair Removal CRANKSHAFT REMOVAL 1. Remove the oil pan assembly. 2. Remove the right side cover. 3. Remove the oil screen. 4. Remove the oil pump. 5. Remove the bolts and the bearing caps. CAUTION: To prevent warpage unscrew the bolts in sequence 1/3 turn at a time, repeat the sequence until all bolts are loosened. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Removal > Page 1868 6. Remove the rod caps/bearings and main caps/bearings. Keep all caps/bearing in order. 7. Lift the crankshaft out of the engine, being careful not to damage journals. 8. Remove the upper bearing halves from the connecting rods and set them aside with their respective caps. 9. Reinstall the main caps and bearings on the engine in proper order. 10. If you can feel ridge of metal or hard carbon around the top of each cylinder, remove it with a ridge reamer. Follow the reamer manufacturer's instructions. CAUTION: If the ridge is not removed, it may damage the pistons as they are pushed out. 11. Use the wooden handle of a hammer to drive the pistons out. 12. Reinstall the connecting rod bearings and caps after removing each piston/connecting rod assembly. 13. Mark each piston/connecting rod assembly with its cylinder number to avoid mix-up on reassembly. NOTE: The existing number on the connecting rod does not indicate its position in the engine, it indicates the rod bore size. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Removal > Page 1869 Crankshaft: Service and Repair Inspection CRANKSHAFT INSPECTION - Clean the crankshaft oil passages with pipe cleaners or a suitable brush. - Check the keyway and threads. ALIGNMENT - Measure runout on all main journals to make sure the crank is not bent. - The difference between measurements on each journal must not be more than the service limit. Crankshaft Total Indicated Runout: Standard (New): 0.03 mm (0.001 inch) max. Service Limit: 0.04 mm (0.002 inch) OUT-OF-ROUND AND TAPER - Measure out-of-round at the middle of each rod and main journal in two places. - The difference between measurements on each journal must not be more than the service limit. Journal Out-of-Round: Standard (New): 0.0025 mm (0.0001 inch) max. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Removal > Page 1870 Service Limit: 0.005 mm (0.0002 inch) - Measure taper at the edges of each rod and main journal. - The difference between measurements on each journal must not be more than the service limit. Journal Taper: Standard (New): 0.0025 mm (0.0001 inch) max. Service Limit: 0.005 mm (0.0002 inch) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Removal > Page 1871 Crankshaft: Service and Repair Installation CRANKSHAFT INSTALLATION NOTE: Before installing the crankshaft, apply a coat of engine oil to the main bearings and rod bearings. 1. Insert the bearing halves into the cylinder block and connecting rods. 2. Hold the crankshaft so the rod journals for cylinders No. 2 and No. 3 are straight down. 3. Lower the crankshaft into the block, seating the rod journals into connecting rods No. 2 and No. 3, and install the rod caps and nuts finger-tight. 4. Rotate the crankshaft clockwise, seat journals into connecting rods No. 1 and No. 4, and install the rod caps and nuts finger-tight. NOTE: Install caps so the bearing recess is on the same side as the recess in the rod. 5. Check rod bearing clearance with plastigage, then torque the cap nuts. Apply engine oil to the bolt threads. Torque: 31 Nm (3.2 kgs.cm, 23 ft.lbs.) NOTE: Reference numbers on connecting rod are for big-end bore tolerance and do not indicate the position of piston in the engine. 6. Install the thrust washers on the No. 4 journal. Oil the thrust washer surfaces. 7. Install the main bearing caps. Check clearance with plastigage, then tighten the bearing cap bolts in 2 steps. First step: 25 Nm (2.5 kgs.cm, 18 ft.lbs.) Second step: 51 Nm (5.2 kgs.cm, 38 ft.lbs.) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Removal > Page 1872 NOTE: Coat the bolt threads with oil. - Use liquid gasket, part No. 08718-0001 or 08718-0003. - Check that the mating surfaces are clean and dry before applying liquid gasket. - Apply liquid gasket evenly, being careful to cover all the mating surface. - To prevent oil leakage, apply liquid gasket to the inner threads of the bolt holes. - Do not install the parts if 5 minutes or more have elapsed since applying the liquid gasket. - Instead reapply liquid gasket after removing the old residue. - After assembly, wait at least 20 minutes before filling the engine with oil. 8. Apply liquid gasket to the block mating surface of the right side cover, then install it on the cylinder block. 9. Apply liquid gasket to the oil pump mating surface of the block, then install the oil pump on the cylinder block. NOTE: Do not apply liquid gasket to O-ring grooves. Apply a light coat of oil to the crankshaft and to the lip of the oil seal. Use new O-rings and apply oil when installing them. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Removal > Page 1873 10. Install the oil screen. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Removal > Page 1874 11. Apply liquid gasket on oil pump and right side cover mating areas. 12. Install the oil pan gasket and oil pan. NOTE: - Use a new oil pan gasket. - Install oil pan no more than five minutes after liquid gasket applied. 13. Tighten nuts finger tight at six points as shown. 14. Tighten all bolts and nuts starting from nut 1 clockwise in three steps. NOTE: Excessive tighting can cause distortion of the oil pan gasket and oil leakage. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Crankshaft Pulley Bolt 134 ft.lb Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair Piston: Service and Repair PISTON NOTE: Refer to Crankshaft Service and Repair for removal procedure.See: Crankshaft/Service and Repair 1. Assemble the special tool as shown. 2. Adjust the length of piston pin driver to 53 mm (2.1 in) as shown. 3. Place the piston on the special tool and press the pin out with a hydraulic press. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Page 1881 Fig. 57 Piston & Connecting Rod Assembly Install piston to rod as shown, Fig. 57. Pistons are available in standard and oversizes of 0.010 and 0.020 inches. NOTE: Before installing the piston, apply a coat of engine oil to the ring grooves and cylinder bores. 1. If the crankshaft is already installed: - Remove the connecting rod caps and slip short sections of rubber hose over the threaded ends of the connecting rod bolts. - Install the ring compressor, check that the bearing is securely in place, then position the piston in the cylinder and tap it in using the wooden handle of a hammer. - Stop after the ring compressor pops free and check the connecting rod-to-crank journal alignment before tapping piston into place. - Install the rod caps with bearings, and torque the nuts to 32 N.m 13.2 kg-m, 23 lb-ft) 2. If the crankshaft is not installed: - Remove the rod caps and bearings, install the ring compressor, then position the piston in the cylinder and tap it in using the wooden handle of a hammer. Position all pistons at top dead center. NOTE: Maintain downward force on the ring compressor to prevent rings from expanding before entering the cylinder bore. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications Piston Pin: Specifications Piston Pin Diameter ............................................................................................................................. ................................................ 0.7478-0.7480 inches Piston Pin To Piston Clearance ............................................................................................................................................................ 0.0004-0.0009 inches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications Piston Diameter (Std.) ......................................................................................................................... ................................................. 2.9520-2.9524 inches Piston Clearance ............................................ ...................................................................................................................................... 0.0004-0.0009 inches Piston Pin Diameter ......................................................................................... .................................................................................... 0.7478-0.7480 inches Piston Pin To Piston Clearance ............................................................................................................................................................ 0.0004-0.0009 inches Piston Ring End Gap: Top ...................................................................................................................................................... ........................................... 0.006-0.012 inches Second ..................................................................... ...................................................................................................................... 0.012-0.018 inches Oil .. .............................................................................................................................................................. .................................. 0.008-0.031 inches Piston Ring To Groove Clearance Top Ring .............................................................................................................................................. ...................................... 0.0012-0.0024 inches Second Ring ............................................................. .................................................................................................................. 0.0012-0.0022 inches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications Valve Clearance: Specifications Valve Clearance Intake ................................................................................................................................................... .......................................... 0.007-0.009 inches Exhaust ................................................................................................................................................ .......................................... 0.009-0.011 inches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications > Page 1892 Valve Clearance: Adjustments VALVE CLEARANCE ADJUSTMENT NOTE: Valves should be adjusted only when the cylinder head temperature is less than 100°F (38°C). Adjustment is the same for intake and exhaust valves. ^ After adjusting, Retorque the crankshaft pulley bolt to 181 Nm (134 ft. lbs.). 1. Remove the cylinder head cover. 2. Set the No. 1 piston at TDC. "UP" mark on the camshaft pulley should be at top, and TDC marks should align with the cylinder head surface. The crankshaft pulley should be at TDC. 3. Adjust valves on No. 1 cylinder. - Intake: 0.18-0.22 mm (0.007-0.009 inch) - Exhaust: 0.23-0.27 mm (0.009-0.011 inch) 4. Loosen the locknut, and turn the adjustment screw until the feeler gauge slides back and forth with a slight amount of drag. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications > Page 1893 CAUTION: Do not overtighten the locknuts; the rocker arms are made of aluminum. 5. Tighten the locknut, and check the clearance again. Repeat the adjustment if necessary. 6. Rotate the crankshaft 180° counterclockwise (camshaft pulley turns 90°). The "UP" mark should be on the exhaust side. Adjust valves on No. 3 cylinder. 7. Rotate the crankshaft 180° counterclockwise to bring No. 4 piston to TDC. Both TDC grooves are once again visible. Adjust valves on No. 4 cylinder. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications > Page 1894 8. Rotate the crankshaft 180° counterclockwise to bring No. 2 piston to TDC. The UP" mark should be on the intake side. Adjust valves on No. 2 cylinder. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair WARNING: Do not smoke while working on the Fuel system. Keep open flames or sparks away from your work area. Be sure to relieve fuel pressure while the Ignition Switch is off. NOTE: Before disconnecting fuel pipes or hoses, release pressure from the system by loosening the 6 mm service bolt on top of the fuel filter. 1. Disconnect the battery negative cable from the battery negative terminal. 2. Remove the fuel fill cap. 3. Use a box end wrench on the 6 mm service bolt at the fuel filter, while holding the special banjo bolt with another wrench. 4. Place a rag or shop towel over the 6 mm service bolt. 5. Slowly loosen the 6 mm service bolt one complete turn. NOTE: A fuel pressure gauge can be attached at the 6 mm service bolt hole. - Always replace the washer between the service bolt and the special banjo bolt whenever the service bolt is loosened. - Replace all washers whenever the bolts are removed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications Rocker Arm Assembly: Specifications ROCKER ARM AND SHAFT TORQUE AND SEQUENCE Cam Holder Torque Sequence Tighten each bolt two turns at a time in the sequence shown to ensure that the rockers do not bind on the valves. SPECIFIED TORQUE: 8mm bolts: 22 Nm (2.2 kg-m, 16 lb.ft.) 6mm bolts: 12 Nm (1.2 kg-m, 9 lb.ft.) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications > Page 1901 Rocker Arm Assembly: Service and Repair Fig. 25 Exploded View Of Rocker Arm Assembly Disassemble one or all parts of rocker arm assembly as necessary, Fig. 25. Prior to removal, identify all parts so they can be installed in their original locations. When removing or installing rocker arm assembly, do not remove camshaft holder bolts. The bolts will keep the holders, springs and rocker arms on the shaft. When reassembling, fit the projection on the intake rocker shaft to the notch in the camshaft holder. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Specifications Valve Guide: Specifications Cylinder Head Warpage Limit .............................................................................................................. ............................................................. 0.002 inches Cylinder Head Minimum Thickness .................. ................................................................................................................................................. 3.738 inches Valve Guides: Standard Inside Diameter .................................................................................................................... ........................................... 0.217-0.218 inches Stem To Guide Clearance: Intake ................................................................................................................................................... .................................... 0.001-0.002 inches Exhaust ........................................................................... ......................................................................................................... 0.002-0.003 inches Valve Seats: Seat Angle, Degrees ........................................................................................................................... ...................................................................... 45 Seat Width: Intake ................................................................................................................................................... ............................................... 0.033-0.045 Exhaust ........................................................................... ......................................................................................................... 0.049-0.061 inches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Specifications > Page 1905 Valve Guide: Service and Repair 1. Heat cylinder head to 300°F (150°C) before removing or installing valve guides. 2. Drive valve guide out bottom of cylinder head using a valve guide driver tool and suitable hammer. 3. Reheat cylinder head if necessary. 4. Using suitable valve guide installation tool, drive valve guide into place until tool bottoms. Reheat cylinder head as necessary. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications Valve Seat: Specifications Cylinder Head Warpage Limit .............................................................................................................. ............................................................. 0.002 inches Cylinder Head Minimum Thickness .................. ................................................................................................................................................. 3.738 inches Valve Guides: Standard Inside Diameter .................................................................................................................... ........................................... 0.217-0.218 inches Stem To Guide Clearance: Intake ................................................................................................................................................... .................................... 0.001-0.002 inches Exhaust ........................................................................... ......................................................................................................... 0.002-0.003 inches Valve Seats: Seat Angle, Degrees ........................................................................................................................... ...................................................................... 45 Seat Width: Intake ................................................................................................................................................... ............................................... 0.033-0.045 Exhaust ........................................................................... ......................................................................................................... 0.049-0.061 inches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications Valve Spring: Specifications Free Length ......................................................................................................................................... ............................................................................. [01] [01] -- Intake valve, 2.043 inches; exhaust valve, 2.176 inches, NIHON HATSUJO; 2.178 inches, CHUO HATSUJO. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Tools - Belt Tension Gauge Calibration and Repair Drive Belt: Technical Service Bulletins Tools - Belt Tension Gauge Calibration and Repair Bulletin No. 96-014 Issue Date Feb. 20, 1996 Model ALL Applicable To ALL File Under SPECIAL TOOLS Belt Tension Gauge Calibration and Repair Tensioning the engine belts properly with the belt tension gauge (T/N 07JGG-001010A) is critical to bearing life of the A/C compressor, alternator, etc. Calibration of the belt tension gauge should be checked regularly. CALIBRATION A Belt Tension Gauge Checker, needed for checking the calibration of the belt tension gauge, is now available. One checker is being automatically shipped to each dealership. Additional checkers may be ordered through normal parts ordering channels. The part number is 07TGG-001010A. Procedure 1. Push the handle and slide the checker into the gauge. Position the checker as shown. 2. Release the handle and read the tension value on the Kg scale. 3. Compare your reading to the value etched on the checker. Your gauge is in calibration if it is within +/- 3 kg of the checker value. If your belt tension gauge is out of calibration, you cannot recalibrate it yourself. Contact America Kowa Seiki about sending it for recalibration. REPLACEMENT PARTS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Tools - Belt Tension Gauge Calibration and Repair > Page 1917 If your belt tension gauge is damaged, replacement parts are available from America Kowa Seiki. They are: REPAIR AND CALIBRATION INFORMATION To order replacement parts for a gauge, contact: America Kowa Seiki 20013 S. Rancho Way Rancho Dominguez, CA 90220 (800) 824-9655 To return your belt tension gauge for calibration: ^ Contact America Kowa Seiki for authorization and shipping instructions. ^ Pack the belt tension gauge in a suitable box. Use "bubble pack" to protect the gauge. ^ Ship according to their instructions. America Kowa Seiki will charge a fixed fee to inspect, clean and calibrate the belt tension gauge, and return it via UPS ground. Any repair parts needed are extra. The gauge will be returned within 15 days. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Page 1918 Drive Belt: Specifications Air Conditioning Deflection, Inches [01]: New ..................................................................................................................................................... .................................................... 0.20-0.28 Used ............................................................................... ......................................................................................................................... 0.26-0.41 Alternator Deflection, Inches [01]: New ..................................................................................................................................................... .................................................... 0.22-0.31 Used ............................................................................... ......................................................................................................................... 0.28-0.41 Power Steering Deflection, Inches [01]: New ..................................................................................................................................................... .................................................... 0.24-0.37 Used ............................................................................... ......................................................................................................................... 0.31-0.47 [01] -- Measured using 22 ft. lbs. force. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Testing and Inspection Engine Oil Pressure: Testing and Inspection OIL PRESSURE TESTING (2.2L engine shown other engines are similar) If the oil pressure warning light stays on with the engine running, check the engine oil level. If the oil level is correct: 1. Connect a tachometer. 2. Remove the engine oil pressure switch and install an oil pressure gauge. 3. Start the engine. Shut it off immediately if the gauge registers no oil pressure. Repair the problem before continuing. 4. Allow the engine to reach operating temperature (fan comes on at least twice). The pressure should be: - Engine Oil Temperature: 176°F (80°C) - Engine Oil Pressure: - At Idle: 69 kPa (10 psi) minimum - At 3,000 rpm: 340 kPa (50 psi) minimum If oil pressure is within specifications, replace the oil pressure switch and recheck. - If oil pressure is NOT within specifications, inspect the oil pump. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine - Oil Recommendation GF-4 Standard Engine Oil: Technical Service Bulletins Engine - Oil Recommendation GF-4 Standard SOURCE: Honda Service News TITLE: Use ONLY New GF-4 Standard Engine Oil APPLIES TO: All Models SERVICE TIP: There's a new performance standard for engine oil: GF-4. It was jointly developed by automotive and oil experts, and it represents a significant performance upgrade and improvement in fuel economy. GF-4 engine oils must pass grueling tests totaling over 500 hours. On top of this, Honda Genuine engine oils are also tested to ensure specific compatibility with Honda vehicles. GF-4 engine oil is compatible with all current and earlier model year Honda cars and trucks. It also provides these added benefits: - Improved oxidation resistance (reduced thickening of the oil) - Improved deposit protection and better wear protection - Better low-temperature performance over the life of the oil - Environmental protection by extending the life of emissions systems While Honda has upgraded its engine oil to GF-4, other brands may not yet be at this new standard. Keep in mind you must use Honda Genuine engine oil for all warranty repairs. If you use some other brand of oil for non-warranty repairs, make sure that oil meets the GF-4 standard. We recommend you stop using non-GF-4 engine oils and check with your supplier that you're purchasing GF-4 oil. Engine oil produced after April 1, 2005, that meets the GF-4 standard, must post this starburst certification mark on the container. Always look for this mark; some oil container labels won't specifically refer to GF-4. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil Capacity For Engine Overhaul ........................................................................................................................................................... 4.0 L (4.2 US qts. 3.5 Imp.qt) For Oil Change, Including Filter ....................................................................................................................................... 3.3 L (3.5 US qts. 2.9 Imp.qts) New standard for engine oil, GF-4. See TSB SN050109 for Honda Service News 050109 for additional information. API Service Grade ............................................................................................................................................ SG or SH "Energy Conserving II" grade oil. Specified viscosities: SAE 5W-30 (Preferred) SAE 10W-30 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1929 Engine Oil: Fluid Type Specifications Engine Oil Capacity For Engine Overhaul ........................................................................................................................................................... 4.0 L (4.2 US qts. 3.5 Imp.qt) For Oil Change, Including Filter ....................................................................................................................................... 3.3 L (3.5 US qts. 2.9 Imp.qts) New standard for engine oil, GF-4. See TSB SN050109 for Honda Service News 050109 for additional information. API Service Grade ............................................................................................................................................ SG or SH "Energy Conserving II" grade oil. Specified viscosities: SAE 5W-30 (Preferred) SAE 10W-30 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair Oil Pan: Service and Repair 1. On manual transmission models, remove flywheel cover. 2. On automatic transmission models, remove drive plate cover. 3. Remove oil pan attaching bolts and nuts, then the oil pan. 4. Reverse procedure to install. Tighten retaining bolts to specification in cross pattern, moving outward from center. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Warning Lamp/Indicator: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1937 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1938 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1939 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1940 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1941 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1942 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1943 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1944 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1945 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1946 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1947 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1948 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1949 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1950 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1951 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1952 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1953 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1954 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1955 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1956 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1957 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1958 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1959 Oil Pressure Warning Lamp/Indicator: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1960 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1961 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1962 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1963 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1964 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1965 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1966 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1967 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1968 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1969 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1970 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1971 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1972 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1973 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1974 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1975 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1976 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1977 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1978 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1979 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1980 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1981 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1982 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1983 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1984 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1985 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1986 Oil Pressure Indicator System Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Testing and Inspection Engine Oil Pressure: Testing and Inspection OIL PRESSURE TESTING (2.2L engine shown other engines are similar) If the oil pressure warning light stays on with the engine running, check the engine oil level. If the oil level is correct: 1. Connect a tachometer. 2. Remove the engine oil pressure switch and install an oil pressure gauge. 3. Start the engine. Shut it off immediately if the gauge registers no oil pressure. Repair the problem before continuing. 4. Allow the engine to reach operating temperature (fan comes on at least twice). The pressure should be: - Engine Oil Temperature: 176°F (80°C) - Engine Oil Pressure: - At Idle: 69 kPa (10 psi) minimum - At 3,000 rpm: 340 kPa (50 psi) minimum If oil pressure is within specifications, replace the oil pressure switch and recheck. - If oil pressure is NOT within specifications, inspect the oil pump. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications Intake Manifold: Specifications For the Specifications for Intake Manifold, go to Engine/Specifications. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Warning Lamp/Indicator: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1999 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2000 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2001 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2002 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2003 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2004 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2005 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2006 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2007 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2008 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2009 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2010 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2011 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2012 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2013 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2014 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2015 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2016 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2017 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2018 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2019 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2020 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2021 Oil Pressure Warning Lamp/Indicator: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2022 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2023 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2024 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2025 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2026 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2027 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2028 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2029 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2030 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2031 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2032 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2033 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2034 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2035 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2036 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2037 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2038 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2039 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2040 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2041 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2042 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2043 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2044 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2045 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2046 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2047 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 2048 Oil Pressure Indicator System Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair Crankshaft Main Bearing Seal: Service and Repair 1. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. 2. Remove engine/transmission assembly. 3. Remove transmission, then the flywheel housing and flywheel. 4. Remove oil pan. 5. Remove oil seal, using seal removal tool. 6. Clean seal seating surfaces thoroughly, apply a light coat of oil to crankshaft and lip of seal and position seal with part number side facing out. 7. Drive seal until it bottoms against block using suitable seal installer tool. 8. Install oil pan and then install engine and transmission assembly in vehicle. 9. Fill crankcase and check for leaks. 10. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Customer Interest for Cylinder Head Gasket: > 97-047 > Nov > 97 > Engine - Cylinder Head Gasket Leaks Cylinder Head Gasket: Customer Interest Engine - Cylinder Head Gasket Leaks 97-047 November 10, 1997 Applies To: 1988 - 95 Civic - All, except VTEC Head Gasket Leaks (Supersedes 97-047, dated September 29, 1997) PROBLEM The head gasket leaks oil externally or allows coolant into the combustion chambers. CORRECTIVE ACTION Install the new style cylinder head gasket and the new head bolts in the Cylinder Gasket Kit listed under PARTS INFORMATION. Use the cylinder head bolt torque sequence described in this bulletin. PARTS INFORMATION Cylinder Gasket Kit: H/C ***0031 Kit includes: Cylinder Head Gasket (new-style): P/N 12251-P01-004, H/C 4489530 Cylinder Head Bolts (10 required, use with new-style gasket): P/N 90005-PM3-004, H/C 2894988 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed part: P/N 12251-PM5-S02 [NEW] H/C 4032470 Defect code: 060 Contention code: B06 Skill level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Remove the cylinder head. (See Cylinder Head Removal in section 6 of the appropriate service manual.) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Customer Interest for Cylinder Head Gasket: > 97-047 > Nov > 97 > Engine - Cylinder Head Gasket Leaks > Page 2061 2. Carefully remove all gasket material from the head and the block with gasket solvent and a heavy duty scraper. The head and block mating surfaces must be clean, flat, and smooth for the new head gasket to seal properly. NOTE: Do not use power tools or abrasives to remove the gasket material; they would damage the head and block surfaces, causing the new head gasket to leak. 3. Before the gasket solvent dries, rinse any pieces of the gasket from the coolant passages in the head and block with water. You must remove all of the gasket material to prevent engine overheating. 4. Install the cylinder head with a new gasket. Do not use any gasket sealers. 5. Apply engine oil to the threads and washers of the new cylinder bolts. Install the bolts, and torque them in the sequence and steps shown. Do not use the head bolt tightening steps in the service manual. Step 1. Tighten all 10 bolts to 20 Nm (14 lb-ft). Step 2. Tighten all 10 bolts to 49 Nm (36 lb-ft). Step 3. Tighten all 10 bolts to 67 Nm (49 lb-ft). Step 4. Tighten bolts 1 and 2 to 67 Nm (49 lb-ft). 6. Reinstall the parts you removed to replace the head gasket. (See Cylinder Head Installation in section 6 of the appropriate service manual.) 7. Test drive the vehicle, and check for external oil leaks. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cylinder Head Gasket: > 97-047 > Nov > 97 > Engine - Cylinder Head Gasket Leaks Cylinder Head Gasket: All Technical Service Bulletins Engine - Cylinder Head Gasket Leaks 97-047 November 10, 1997 Applies To: 1988 - 95 Civic - All, except VTEC Head Gasket Leaks (Supersedes 97-047, dated September 29, 1997) PROBLEM The head gasket leaks oil externally or allows coolant into the combustion chambers. CORRECTIVE ACTION Install the new style cylinder head gasket and the new head bolts in the Cylinder Gasket Kit listed under PARTS INFORMATION. Use the cylinder head bolt torque sequence described in this bulletin. PARTS INFORMATION Cylinder Gasket Kit: H/C ***0031 Kit includes: Cylinder Head Gasket (new-style): P/N 12251-P01-004, H/C 4489530 Cylinder Head Bolts (10 required, use with new-style gasket): P/N 90005-PM3-004, H/C 2894988 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed part: P/N 12251-PM5-S02 [NEW] H/C 4032470 Defect code: 060 Contention code: B06 Skill level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Remove the cylinder head. (See Cylinder Head Removal in section 6 of the appropriate service manual.) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cylinder Head Gasket: > 97-047 > Nov > 97 > Engine - Cylinder Head Gasket Leaks > Page 2067 2. Carefully remove all gasket material from the head and the block with gasket solvent and a heavy duty scraper. The head and block mating surfaces must be clean, flat, and smooth for the new head gasket to seal properly. NOTE: Do not use power tools or abrasives to remove the gasket material; they would damage the head and block surfaces, causing the new head gasket to leak. 3. Before the gasket solvent dries, rinse any pieces of the gasket from the coolant passages in the head and block with water. You must remove all of the gasket material to prevent engine overheating. 4. Install the cylinder head with a new gasket. Do not use any gasket sealers. 5. Apply engine oil to the threads and washers of the new cylinder bolts. Install the bolts, and torque them in the sequence and steps shown. Do not use the head bolt tightening steps in the service manual. Step 1. Tighten all 10 bolts to 20 Nm (14 lb-ft). Step 2. Tighten all 10 bolts to 49 Nm (36 lb-ft). Step 3. Tighten all 10 bolts to 67 Nm (49 lb-ft). Step 4. Tighten bolts 1 and 2 to 67 Nm (49 lb-ft). 6. Reinstall the parts you removed to replace the head gasket. (See Cylinder Head Installation in section 6 of the appropriate service manual.) 7. Test drive the vehicle, and check for external oil leaks. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Camshaft Pulley Bolt 27 ft.lb Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Diagrams Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Diagrams > Page 2075 Timing Belt: Testing and Inspection TIMING BELT INSPECTION NOTE: - Replace the belt if oil or coolant soaked. - Remove any oil or solvent that gets on the belt. 1. Remove the cylinder head cover. 2. Remove the timing belt upper cover. 3. Inspect the timing belt for cracks and oil or coolant soaking. 4. After inspecting, retorque the crankshaft pulley bolt to specified torque. Specified Torque: 185 N.m (18.5 kg-m, 134 lb-ft) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Diagrams > Page 2076 Timing Belt: Adjustments TIMING BELT TENSION ADJUSTMENT CAUTION: Always adjust the timing belt tension with the engine cold. NOTE: - The tensioner is spring-loaded to apply proper tension to the belt automatically after making the following adjustment. - Always rotate the crankshaft counterclockwise when viewed from the pulley side. Rotating it clockwise may result in improper adjustment of the belt tension. 1. Remove the cylinder head cover. 2. Remove the timing belt upper cover. 3. Set the No.1 piston at top dead center (TDC). 4. Loosen the adjusting bolt 180°. 5. Rotate the crankshaft counterclockwise 3-teeth on the camshaft pulley to create tension on the timing belt. 6. Make sure the timing belt and the camshaft pulley are engaged securely. 7. Torque the adjusting bolt to 45 N.m (4.5 kg-m, 33 lb-ft). 8. After adjusting, retorque the crankshaft pulley bolt to specified torque. Specified Torque: 185 N.m (18.5 kg-m, 134 lb-ft) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Diagrams > Page 2077 Timing Belt: Service and Repair TIMING BELT REMOVAL CAUTION: Inspect the water pump when replacing the timing belt. NOTE: Turn the crankshaft so that No.1 piston is at top-dead-center. - Before removing the timing belt, mark its direction of rotation if it to be reused. 1. Remove the splash shield. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Diagrams > Page 2078 2. Remove the power steering pump. - Do not disconnect the P/S hoses. 3. On vehicles with A/C remove the A/C compressor adjusting pulley with bracket and the belt. 4. Remove the P/S bracket. 5. Loosen the alternator adjusting bolt and pivot nut, then remove the belt. 6. Remove the cruise control actuator. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Diagrams > Page 2079 7. Remove the engine support nuts. Loosen the mount bolt and pivot the side engine mount out of the way. 8. Remove the cylinder head cover. 9. Remove the timing belt upper cover. 10. Remove the special bolt and crankshaft pulley. 11. Remove the timing belt upper cover and the lower cover. 12. Loosen the timing belt adjusting bolt 180°. 13. Push the tensioner to release tension from the belt, then retighten the adjusting bolt. 14. Remove the timing belt from the pulleys. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Diagrams > Page 2080 TIMING BELT INSTALLATION 1. Install the timing belt in the reverse order of removal; Only key points are described here. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Diagrams > Page 2081 2. Position the crankshaft and the camshaft pulleys as shown before installing the timing belt. A. Set the crankshaft so that the No.1 piston is at top dead center (TDC). Align the groove on the teeth side of the timing belt drive pulley to the pointer on the oil pump. B. Align the TDC marks on the camshaft pulley with the cylinder head upper surface. 3. Install the timing belt tightly in the sequence shown. (1) Timing belt drive pulley (crankshaft) -> (2) Adjusting pulley -> (3) Water pump pulley -> (4) Camshaft pulley. 4. Loosen the adjusting bolt, and retighten it after tensioning the belt. 5. Rotate the crankshaft about 4 or 6 turns counterclockwise so that the belt positions on the pulleys. 6. Adjust the timing belt tension. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Diagrams > Page 2082 Crankshaft Pulley Camshaft Pulley 7. Check the crankshaft pulley and the camshaft pulley at TDC. 8. If the camshaft pulley is not positioned at TDC remove the timing belt and adjust the positioning and repeat the installation procedure and reinstall the timing belt. After installation, adjust the tension of each belt. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt Tensioner > Component Information > Specifications Timing Belt Tensioner: Specifications Tensioner Adjusting Bolt 33 ft.lb Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications Timing Cover Bolts 7 ft.lb Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions Variable Valve Timing Actuator: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2094 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2095 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2096 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2097 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2098 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2099 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2100 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2101 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2102 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2103 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2104 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2105 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2106 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2107 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2108 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2109 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2110 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2111 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2112 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2113 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2114 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2115 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2116 Variable Valve Timing Actuator: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2117 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2118 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2119 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2120 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2121 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2122 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2123 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2124 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2125 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2126 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2127 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2128 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2129 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2130 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2131 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2132 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2133 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2134 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2135 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2136 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2137 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2138 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2139 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2140 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2141 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2142 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Pressure Switch > Component Information > Diagrams Variable Valve Timing Pressure Switch: Diagrams For Connector Views refer to "Powertrain Management : Diagrams". Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > Tools - New Fuel Pressure Gauge and Replacement Parts Fuel Pressure: Technical Service Bulletins Tools - New Fuel Pressure Gauge and Replacement Parts 97-020 MAR 10, 1997 Applies To: ALL Models New Fuel Pressure Gauge and Replacement Parts New Gauge The fuel pressure gauge with 10" hose (T/N 07406-0040001) has been discontinued. The gauge that replaces it (T/N 07406-004000A) has an easier-to-read face, a protective boot around the gauge housing, and a 48" hose. Replacement Parts Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > Tools - New Fuel Pressure Gauge and Replacement Parts > Page 2151 The replacement hose for the old gauge (24", T/N 07406-004020A) has also been discontinued. If you need a replacement hose, order the new 48" hose (T/N 07406-004020B). The new hose comes with an adapter so you can use it with the old fuel pressure gauge (T/N 07406-0040001). Before connecting the hose to the vehicle, make sure the aluminum washer on the end of the hose seals properly. If the aluminum washer doesn't seal, replace the washer. Replacement washers come in a set of five (T/N 07406-0040300). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > Page 2152 Fuel Pressure: Specifications At Curb Idle With Vacuum Hose Connected ....................................................................................................................................................... 215-265 kPa (31-38 psi) With Vacuum Hose Disconnected ................................................................................................................................................... 280-330 kPa (40-47 psi) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > Page 2153 Fuel Pressure: Testing and Inspection 1. Relieve fuel pressure. 2. Remove the service bolt on the fuel filter while holding the banjo bolt with another wrench. Attach the special tool. 3. Start the engine *. Measure the fuel pressure with the engine idling and vacuum hose of the fuel pressure regulator disconnected from the fuel pressure regulator and pinched. Pressure should be: 280-330 kPa (2.8-3.3 kg/cm2, 40-47 psi) 4. Reconnect vacuum hose to the fuel pressure regulator. Pressure should be: 215-265 kPa (2.15-2.65 kg/cm2, 31-38 psi) ^ If the engine will not start, turn the ignition switch on, wait for two seconds, turn it off, then back on again and read the fuel pressure. ^ If the fuel pressure is not as specified, first check the fuel pump. If the fuel is OK, check the following: ^ If the fuel pressure is higher than specified, inspect for: Pinched or clogged fuel return hose or piping. - Faulty fuel pressure regulator. ^ If the fuel pressure is lower than specified, inspect for: Clogged fuel filter. - Faulty fuel pressure regulator. Leakage in the fuel hoses or pipes. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Adjustments Air/Fuel Mixture: Adjustments The Air/Fuel mixture is controlled by the engine control module and is not adjustable. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications IDLE SPEED Manual transmission ............................................................................................................................ ................................................. 670 RPM [01] Automatic transmission .............................................. ........................................................................................................................... 670 RPM [01] [01] -- Transmission in Neutral or Park, headlights and cooling fan OFF. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 2160 Idle Speed: Testing and Inspection 1. Start the engine and allow it to warm-up (the radiator fan comes on). 2. Connect a tachometer to the test tachometer connector. NOTE: All electrical systems should be turned OFF. IDLE SPEED: (M/T) in neutral: (USA): 670 ± 50 rpm (Canada): 750 ± 50 rpm (A/T) in [N] or [P]: (USA): 700 ± 50 rpm (Canada): 750 ± 50 rpm 3. Adjust the idle speed, if necessary. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 2161 Idle Speed: Adjustments NOTE: ^ When the idle speed set, check the following items: The MIL has not been reported on. - Ignition timing - Spark plugs - Air cleaner - PCV system ^ (Canada) Pull the parking brake lever up. Start the engine, then check that the headlights are off. 1. Start the engine. Hold the engine at 3,000 rpm with no load (A/T in [N] or [P] position, M/T in neutral) until the radiator fan comes on, then let it idle. 2. Connect a tachometer. 3. Disconnect the 2P connector from the Idle Air Control (IAC) valve. 4. Start the engine with the accelerator pedal slightly depressed. Stabilize the rpm at 1,000, then slowly release the pedal until the engine idles. 5. Check idling in no-load conditions: headlights, blower fan, rear defogger, radiator fan, and air conditioning are not operating. Idle speed should be: M/T D15Z1 engine: 420 +/- 50 rpm Others: 420 +/- 50 rpm A/T 420 +/- 50 rpm (in [N] or [P] position) Adjust the idle speed, if necessary, by turning the idle adjusting screw. NOTE: After adjusting the idle speed in this step, check the ignition timing. If it is out of spec, go back to step 4. 6. Turn the ignition switch OFF. 7. Reconnect the 2P connector on the IAC valve, then remove BACK UP (7.5 A) fuse in the under-hood fuse/relay box for 10 seconds to reset the ECM. 8. Restart and idle the engine with no-load conditions for one minute, then check the idle speed. NOTE: (Canada) Pull the parking brake lever up. Start the engine, then check that the headlights are off. Idle speed should be: Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 2162 M/T D15Z1 engine: 600 +/- 50 rpm Others: 670 +/- 50 rpm A/T 700 +/- 50 rpm (in [N] or [P] position) 9. Idle the engine for one minute with headlights (Low) ON and check the idle speed. Idle speed should be: M/T D15Z1 engine: 700 +/- 50 rpm Others: 750 +/- 50 rpm A/T 750 +/- 50 rpm (in [N] or [P] position) 10. Turn the headlights off. Idle the engine for one minute with heater fan switch at HI and air conditioner on, then check the idle speed. Idle speed should be: M/T D15Z1 engine: 810 +/- 50 rpm Others: 810 +/- 50 rpm A/T 810 +/- 50 rpm (in [N] or [P] position) NOTE: If the idle speed is not within specification, see System Troubleshooting Guide. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component Information > Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair WARNING: Do not smoke while working on the Fuel system. Keep open flames or sparks away from your work area. Be sure to relieve fuel pressure while the Ignition Switch is off. NOTE: Before disconnecting fuel pipes or hoses, release pressure from the system by loosening the 6 mm service bolt on top of the fuel filter. 1. Disconnect the battery negative cable from the battery negative terminal. 2. Remove the fuel fill cap. 3. Use a box end wrench on the 6 mm service bolt at the fuel filter, while holding the special banjo bolt with another wrench. 4. Place a rag or shop towel over the 6 mm service bolt. 5. Slowly loosen the 6 mm service bolt one complete turn. NOTE: A fuel pressure gauge can be attached at the 6 mm service bolt hole. - Always replace the washer between the service bolt and the special banjo bolt whenever the service bolt is loosened. - Replace all washers whenever the bolts are removed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > System Check Connector <--> [Ignition Timing Connector] > Component Information > Locations > Component Locations System Check Connector: Component Locations The Service Check Connector is located behind the glove box. CAUTION: Do not use a jumper wire on the Data Link Connector. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > System Check Connector <--> [Ignition Timing Connector] > Component Information > Locations > Component Locations > Page 2178 System Check Connector: Connector Locations The Service Check Connector is located behind the glove box. CAUTION: Do not use a jumper wire on the Data Link Connector. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Timing Marks and Indicators > System Information > Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications Resistance at 20°C (68°F) ................................................................................................................... ......................................................... 25 K Ohms max Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions Ignition Cable: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 2190 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 2191 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 2192 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 2193 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 2194 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 2195 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 2196 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 2197 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 2198 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 2199 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 2200 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 2201 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 2202 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 2203 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 2204 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 2205 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 2206 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 2207 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 2208 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 2209 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 2210 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 2211 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 2212 Ignition Cable: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 2213 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 2214 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 2215 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 2216 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 2217 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 2218 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 2219 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 2220 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 2221 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 2222 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 2223 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 2224 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 2225 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 2226 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 2227 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 2228 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 2229 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 2230 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 2231 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 2232 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 2233 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 2234 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 2235 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 2236 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 2237 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 2238 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Page 2239 Ignition Cable: Testing and Inspection CAUTION: Carefully remove the ignition wires by pulling on the rubber boots. Do not bend the wires; you might break them inside. 1. Check the condition of the wire terminals. If any terminal is corroded, clean it, and if it is broken or distorted, replace the wire. 2. Connect ohmmeter probes and measure resistance. Resistance: 25 k Ohms max. at 70° F (20°C) 3. If resistance exceeds 25 k Ohms, replace the ignition wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Cap > Component Information > Testing and Inspection Distributor Cap: Testing and Inspection Check the following points, repair or replace as needed if a problem is found. 1. There must be no cracking in the cap. 2. There must be no damage to the cap's electrodes. 3. Clean away any accumulated dirt from the cap. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Testing and Inspection Ignition Rotor: Testing and Inspection Check the following points, repair or replace as needed if a problem is found. 1. There must be no cracking in the rotor. 2. There must be no damage to the rotor's electrode. 3. Clean away any accumulated dirt from the rotor. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap and Torque Spark Plug: Specifications Gap and Torque Spark Plug Gap ................................................................................................................................... ........................................................ 1.1 mm (0.043 in) Spark Plug Torque ............................................................................................................................... ......................................................... 18 Nm (13 ft lb) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap and Torque > Page 2251 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2252 Spark Plug: Testing and Inspection Spark Plug Inspection 1. Inspect the electrodes and ceramic insulator for: Burned or worn electrodes may be caused by: ^ Advanced ignition timing ^ Loose spark plug ^ Plug heat range too low ^ Insufficient cooling Fouled plug may be caused by: ^ Retarded ignition timing ^ Oil in combustion chamber ^ Incorrect spark plug gap ^ Plug heat range too high ^ Excessive idling/low speed running ^ Clogged air cleaner element ^ Deteriorated ignition coil or ignition wires 2. Adjust the gap with a suitable gapping tool. 3. Replace the plug if the center electrode is rounded as shown above. NOTE: Do not use spark plugs other than recommended types. These plugs are a new type (ISO standard). 4. Screw the plugs into the cylinder head finger tight, then torque them to 18 N-m (1.8 kg-m, 13 lb-ft). NOTE: Apply a small quantity of anti-seize compound to the plug threads before installing. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Check compression with engine at normal operating temperature and throttle in wide open position. Prior to performing test, disable ignition and fuel injection to prevent fuel from being sprayed into cylinders while cranking engine. Ensure is fully charged and that cranking speed is 250 RPM. Standard reading should be 135-184 psi. The maximum variation between cylinders is 28 psi. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications Valve Clearance Intake ................................................................................................................................................... .......................................... 0.007-0.009 inches Exhaust ................................................................................................................................................ .......................................... 0.009-0.011 inches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 2259 Valve Clearance: Adjustments VALVE CLEARANCE ADJUSTMENT NOTE: Valves should be adjusted only when the cylinder head temperature is less than 100°F (38°C). Adjustment is the same for intake and exhaust valves. ^ After adjusting, Retorque the crankshaft pulley bolt to 181 Nm (134 ft. lbs.). 1. Remove the cylinder head cover. 2. Set the No. 1 piston at TDC. "UP" mark on the camshaft pulley should be at top, and TDC marks should align with the cylinder head surface. The crankshaft pulley should be at TDC. 3. Adjust valves on No. 1 cylinder. - Intake: 0.18-0.22 mm (0.007-0.009 inch) - Exhaust: 0.23-0.27 mm (0.009-0.011 inch) 4. Loosen the locknut, and turn the adjustment screw until the feeler gauge slides back and forth with a slight amount of drag. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 2260 CAUTION: Do not overtighten the locknuts; the rocker arms are made of aluminum. 5. Tighten the locknut, and check the clearance again. Repeat the adjustment if necessary. 6. Rotate the crankshaft 180° counterclockwise (camshaft pulley turns 90°). The "UP" mark should be on the exhaust side. Adjust valves on No. 3 cylinder. 7. Rotate the crankshaft 180° counterclockwise to bring No. 4 piston to TDC. Both TDC grooves are once again visible. Adjust valves on No. 4 cylinder. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 2261 8. Rotate the crankshaft 180° counterclockwise to bring No. 2 piston to TDC. The UP" mark should be on the intake side. Adjust valves on No. 2 cylinder. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair Water Pump: Service and Repair When refilling cooling system, bleed cooling system to let out any trapped air. 1. Drain cooling system into suitable container. 2. Remove timing belt as outlined under Timing Belt. 3. Remove water pump attaching bolts, then the water pump. 4. Reverse procedure to install. Tighten water pump attaching bolts to specifications. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Coolant Capacity, Quarts: Man. Transmission .............................................................................................................................. .................................................................. 4.76 Auto. Transmission ................................................... .............................................................................................................................................. 4.6 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 2270 Coolant: Fluid Type Specifications Coolant/Anti-freeze Ethylene Glycol Based Coolant Concentration Minimum 50 % Maximum 60 % Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Locations Radiator Cooling Fan Motor: Locations Right Front Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions Radiator Cooling Fan Motor: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2277 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2278 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2279 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2280 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2281 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2282 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2283 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2284 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2285 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2286 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2287 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2288 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2289 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2290 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2291 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2292 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2293 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2294 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2295 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2296 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2297 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2298 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2299 Radiator Cooling Fan Motor: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2300 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2301 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2302 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2303 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2304 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2305 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2306 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2307 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2308 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2309 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2310 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2311 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2312 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2313 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2314 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2315 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2316 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2317 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2318 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2319 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2320 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2321 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2322 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2323 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2324 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2325 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2326 Radiator Cooling Fan Motor: Electrical Diagrams Fans- With A/C (Part 1 Of 2) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2327 Fans- With A/C (Part 2 Of 2) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2328 Fans- Without A/C Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 2329 Radiator Cooling Fan Motor: Description and Operation Voltage is provided at all times to the radiator fan relay (contacts) through fuse 33. With the ignition switch in ON (II), voltage is provided to the coil of the relay through fuse 13. The radiator fan relay can be grounded through either the engine coolant temperature switch or the Engine Control Module (ECM). The engine coolant temperature switch grounds the radiator fan relay (coil) when the engine coolant temperature exceeds 199°F (93°C). The switch opens when coolant temperature decreases 3°-8°C. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 2330 Radiator Cooling Fan Motor: Testing and Inspection 1. Disconnect electrical connector to fan motor. 2. Connect battery voltage across motor terminals using suitable jumper wires. 3. If fan fails to operate, motor is defective. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Right Rear Corner Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 2334 Radiator Cooling Fan Motor Relay: Testing and Inspection Fig. 10 Cooling Fan Relay Terminal Identification 1. Disconnect electrical connector and remove relay. 2. Connect ohmmeter between relay terminals A and B, Fig. 10. 3. Meter should indicate no continuity. 4. Connect battery voltage across terminals C and D. 5. With relay energized, ohmmeter should indicate continuity between terminals A and B. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Locations Water Pump Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Locations > Page 2338 Radiator Cooling Fan Temperature Sensor / Switch: Testing and Inspection 1. Drain cooling system and remove cooling fan temp switch from the thermostat housing. 2. Connect suitable ohmmeter between sensor terminals. 3. Heat thermo sensor in suitable solution while observing ohmmeter. 4. Meter should indicate continuity when temperature reaches 190-0.03degreesF. 5. Allow sensor to cool while observing meter. Meter should indicate no continuity as temperature drops below approximately 182-188degreesF. 6. If sensor fails to operate as outlined, sensor is defective. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Photo 9 Coolant Temperature Sensor/Switch (For Computer): Locations Photo 9 Right Side Of Engine. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Photo 9 > Page 2344 Coolant Temperature Sensor/Switch (For Computer): Locations Photo 14 Right Front Of Engine. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2345 Coolant Temperature Sensor/Switch (For Computer): Description and Operation PURPOSE/DESCRIPTION The engine coolant temperature sensor is a temperature dependant resistor (thermistor) that convents the engine coolant temperature to voltage and outputs it to the engine control module. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Locations Water Pump Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Locations > Page 2349 Radiator Cooling Fan Temperature Sensor / Switch: Testing and Inspection 1. Drain cooling system and remove cooling fan temp switch from the thermostat housing. 2. Connect suitable ohmmeter between sensor terminals. 3. Heat thermo sensor in suitable solution while observing ohmmeter. 4. Meter should indicate continuity when temperature reaches 190-0.03degreesF. 5. Allow sensor to cool while observing meter. Meter should indicate no continuity as temperature drops below approximately 182-188degreesF. 6. If sensor fails to operate as outlined, sensor is defective. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Locations Temperature Sensor (Gauge): Locations Right Front Of Engine. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Control Valve > Heater Control Valve Cable > Component Information > Technical Service Bulletins > A/C - Heater Blows Cold Air/A/C Blows Hot Air Heater Control Valve Cable: Technical Service Bulletins A/C - Heater Blows Cold Air/A/C Blows Hot Air Heater Blows Cold Air; A/C Blows Warm Air NOTE: This article applies to all A/C-equipped Honda models that use a heater valve cable. Got a vehicle in your shop that blows cold air from the heater or warm air from the A/C? The problem could just be the heater valve cable has slipped off the heater valve arm. There's a real easy fix for this problem. Slip the heater valve cable back onto the heater valve arm. Then cut yourself a 10 mm length of 3.5 mm vacuum hose (P/N 95005-35008-10M, H/C 2325058), and slide it onto the arm. This holds the cable on the arm nice and snug so it won't slip off. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Control Valve > Heater Control Valve Cable > Component Information > Technical Service Bulletins > A/C - Heater Blows Cold Air/A/C Blows Hot Air > Page 2358 Heater Control Valve Cable: Technical Service Bulletins A/C - Heater Blows Cold Air, A/C Blows Warm Air SOURCE: Honda Service News TITLE: Heater Blows Cold Air, A/C Blows Warm Air APPLIES TO: all A/C-equipped Honda models that use a heater valve cable. SERVICE TIP: Got a vehicle in your shop that blows cold air from the heater or warm air from the A/C ? The problem could just be the heater valve cable has slipped off the heater valve arm. There's a real easy fix for this problem. Slip the heater valve cable back onto the heater valve arm. Then cut yourself a 10 mm length of 3.5 mm vacuum hose and slide it onto the arm. This holds the cable on the arm nice and snug so it won't slip off. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Diagrams > Diagram Information and Instructions Heater Core: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 2363 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 2364 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 2365 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 2366 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 2367 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 2368 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 2369 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 2370 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 2371 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 2372 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 2373 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 2374 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 2375 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 2376 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 2377 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 2378 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 2379 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 2380 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 2381 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 2382 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 2383 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 2384 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 2385 Heater Core: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 2386 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 2387 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 2388 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 2389 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 2390 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 2391 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 2392 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 2393 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 2394 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 2395 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 2396 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 2397 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 2398 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 2399 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 2400 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 2401 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 2402 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 2403 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 2404 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 2405 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 2406 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 2407 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 2408 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 2409 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 2410 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 2411 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Diagrams > Page 2412 Heater Core: Service and Repair 1. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. 2. Disconnect battery ground cable, then drain cooling system. 3. Snap open cable clip, then disconnect heater valve cable from heater valve. 4. Disconnect heater hoses at heater, then remove heater unit mounting nut from engine compartment side. 5. Remove instrument panel. 6. Remove heat duct or evaporator and steering column bracket. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Diagrams > Page 2413 7. Remove clip, heater mounting nuts and heater assembly. Fig. 16 Heater Core Removal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Diagrams > Page 2414 8. Remove heater core cover attaching screws, then the cover, Fig. 16. 9. Remove pipe clamp and damper arm attaching screws. 10. Pull heater core from heater housing. Ensure care is taken not to bend inlet and outlet pipes during removal. 11. Reverse procedure to install, noting the following: a. Do not interchange inlet and outlet hoses. b. Connect all cables and ensure they are properly adjusted. 12. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. 13. After refilling cooling system, bleed cooling system. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Description and Operation Temperature Gauge: Description and Operation When the ignition switch is in ON (II) or START (III), battery voltage is supplied through fuse 15 to the gauges in the gauge assembly. The Engine Coolant Temperature (ECT) gauge has two intersecting coils wound around a permanent magnet rotor. Voltage applied to the coils, through fuse 15, generates a magnetic field. The magnetic field, controlled by the coolant temperature sending unit, causes the rotor to rotate and the gauge needle to move. As the resistance in the sending unit varies, current through the gauge coils changes. The gauge needle moves toward the coil with the strongest magnetic field. The fuel gauge works the same way. The engine coolant temperature (ECT) sending unit's resistance varies from about 137 ohms at low engine temperature to between 30-46 ohms at high temperature (radiator fan running). The fuel gauge sending unit's resistance varies from about 2-5 ohms at full, to about 110 ohms at empty. When you turn the ignition switch OFF, the gauge remains at the last reading until you turn the ignition switch to ON (II) or START (III) again. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Description and Operation > Page 2419 Temperature Gauge: Testing and Inspection 1. Check No. 15 (10A) fuse in under dash fuse/relay box before testing. Fig. 1 Engine Coolant Temperature Unit 2. Ensure ignition switch is in Off position, then disconnect yellow/green wire from coolant temperature sending unit, Fig. 1, and ground it with a jumper wire. 3. Turn ignition switch to On position. 4. Check as needle of coolant temperature gauge starts moving toward H mark. Turn ignition switch to Off position before pointer reaches H mark on gauge dial. Failure to do so may damage gauge. 5. If pointer of gauge does not move, check the following: a. Blown fuse in under dash fuse/relay box. b. Open in yellow/green wire, yellow or red wire. c. If fuse and wiring are satisfactory, replace coolant temperature gauge. 6. If gauge is satisfactory, inspect sending unit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair Radiator: Service and Repair Fig. 73 Exploded View Of Radiator Assembly 1. Drain engine coolant, then radiator hoses and ATF cooler hoses, Fig. 73. 2. Disconnect fan motor electrical connections, then remove radiator upper brackets. 3. Pull up and remove radiator, then remove fan shroud assemblies and other parts as necessary. 4. Reverse procedure to install. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Specifications Radiator Cap: Specifications Radiator Cap Pressure Relief .............................................................................................................. .................................................................... 14-18 psi Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Right Rear Corner Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 2430 Radiator Cooling Fan Motor Relay: Testing and Inspection Fig. 10 Cooling Fan Relay Terminal Identification 1. Disconnect electrical connector and remove relay. 2. Connect ohmmeter between relay terminals A and B, Fig. 10. 3. Meter should indicate no continuity. 4. Connect battery voltage across terminals C and D. 5. With relay energized, ohmmeter should indicate continuity between terminals A and B. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Photo 9 Coolant Temperature Sensor/Switch (For Computer): Locations Photo 9 Right Side Of Engine. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Photo 9 > Page 2437 Coolant Temperature Sensor/Switch (For Computer): Locations Photo 14 Right Front Of Engine. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2438 Coolant Temperature Sensor/Switch (For Computer): Description and Operation PURPOSE/DESCRIPTION The engine coolant temperature sensor is a temperature dependant resistor (thermistor) that convents the engine coolant temperature to voltage and outputs it to the engine control module. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Locations Water Pump Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Locations > Page 2442 Radiator Cooling Fan Temperature Sensor / Switch: Testing and Inspection 1. Drain cooling system and remove cooling fan temp switch from the thermostat housing. 2. Connect suitable ohmmeter between sensor terminals. 3. Heat thermo sensor in suitable solution while observing ohmmeter. 4. Meter should indicate continuity when temperature reaches 190-0.03degreesF. 5. Allow sensor to cool while observing meter. Meter should indicate no continuity as temperature drops below approximately 182-188degreesF. 6. If sensor fails to operate as outlined, sensor is defective. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Locations Temperature Sensor (Gauge): Locations Right Front Of Engine. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Description and Operation Temperature Gauge: Description and Operation When the ignition switch is in ON (II) or START (III), battery voltage is supplied through fuse 15 to the gauges in the gauge assembly. The Engine Coolant Temperature (ECT) gauge has two intersecting coils wound around a permanent magnet rotor. Voltage applied to the coils, through fuse 15, generates a magnetic field. The magnetic field, controlled by the coolant temperature sending unit, causes the rotor to rotate and the gauge needle to move. As the resistance in the sending unit varies, current through the gauge coils changes. The gauge needle moves toward the coil with the strongest magnetic field. The fuel gauge works the same way. The engine coolant temperature (ECT) sending unit's resistance varies from about 137 ohms at low engine temperature to between 30-46 ohms at high temperature (radiator fan running). The fuel gauge sending unit's resistance varies from about 2-5 ohms at full, to about 110 ohms at empty. When you turn the ignition switch OFF, the gauge remains at the last reading until you turn the ignition switch to ON (II) or START (III) again. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Description and Operation > Page 2449 Temperature Gauge: Testing and Inspection 1. Check No. 15 (10A) fuse in under dash fuse/relay box before testing. Fig. 1 Engine Coolant Temperature Unit 2. Ensure ignition switch is in Off position, then disconnect yellow/green wire from coolant temperature sending unit, Fig. 1, and ground it with a jumper wire. 3. Turn ignition switch to On position. 4. Check as needle of coolant temperature gauge starts moving toward H mark. Turn ignition switch to Off position before pointer reaches H mark on gauge dial. Failure to do so may damage gauge. 5. If pointer of gauge does not move, check the following: a. Blown fuse in under dash fuse/relay box. b. Open in yellow/green wire, yellow or red wire. c. If fuse and wiring are satisfactory, replace coolant temperature gauge. 6. If gauge is satisfactory, inspect sending unit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications Thermostat: Specifications Thermostat Opening Temperature ...................................................................................................... .......................................................................... 172°F Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 2453 Thermostat: Service and Repair Fig. 67 Thermostat Replacement Refer to Fig. 67, for thermostat replacement. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair Water Pump: Service and Repair When refilling cooling system, bleed cooling system to let out any trapped air. 1. Drain cooling system into suitable container. 2. Remove timing belt as outlined under Timing Belt. 3. Remove water pump attaching bolts, then the water pump. 4. Reverse procedure to install. Tighten water pump attaching bolts to specifications. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Three Way Catalytic (TWC) Converter <--> [Catalytic Converter] > Component Information > Technical Service Bulletins > Exhaust System - Catalytic Converter Noise Three Way Catalytic (TWC) Converter: Technical Service Bulletins Exhaust System - Catalytic Converter Noise SOURCE: Honda Service News TITLE: Catalytic Converter Noise? Check the Heat Shield APPLIES TO: All models SERVICE TIP: Got a vehicle in your shop that buzzes or rattles, and you suspect the catalytic converter is the culprit? Before you start replacing the converter, first check the heat shield area. If there any stones or debris trapped inside, they can cause buzzing or rattling. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Three Way Catalytic (TWC) Converter <--> [Catalytic Converter] > Component Information > Technical Service Bulletins > Page 2462 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Three Way Catalytic (TWC) Converter <--> [Catalytic Converter] > Component Information > Technical Service Bulletins > Page 2463 Three Way Catalytic (TWC) Converter: Description and Operation PURPOSE/OPERATION The Three Way Catalytic Converter (TWC) is used to convert Hydrocarbons (HC), Carbon Monoxide (CO), and Oxides of Nitrogen (NOx) in the exhaust gas, to Carbon Dioxide (CO2), Dinitrogen (N2) and water vapor. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Three Way Catalytic (TWC) Converter <--> [Catalytic Converter] > Component Information > Technical Service Bulletins > Page 2464 Three Way Catalytic (TWC) Converter: Testing and Inspection INSPECTION If excessive exhaust system back-pressure is suspected, remove the TWC from the car and make a visual check for plugging, melting or cracking of the Catalyst. Replace the TWC if any of the visible area is damaged or plugged. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations Body Control Module: Locations Rear Of Under-dash Fuse/Relay Box Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2473 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2474 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2475 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2476 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2477 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2478 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2479 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2480 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2481 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2482 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2483 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2484 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2485 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2486 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2487 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2488 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2489 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2490 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2491 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2492 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2493 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2494 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2495 Body Control Module: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2496 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2497 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2498 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2499 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2500 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2501 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2502 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2503 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2504 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2505 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2506 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2507 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2508 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2509 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2510 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2511 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2512 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2513 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2514 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2515 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2516 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2517 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2518 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2519 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2520 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2521 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors Engine Control Module: Technical Service Bulletins Emissions - OBD II DTC's And Associated Monitors 03-020 April 2, 2010 Applies To: All OBD II-equipped models except Passport OBD II DTCs and Their Associated Monitors (Supersedes 03-020, dated March 29, 2003, to revise the information marked by the black bars and asterisks) *REVISION SUMMARY Numerous DTCs were added. Refer to the list for details.* Following is a list of all OBD II DTCs and their associated monitors for all Honda automobiles with OBD II. No one model has every DTC in the list. DTC P0AA6 thru P0A9E Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 2526 DTC P0A94 thru P0157 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 2527 DTC P0158 thru P0400 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 2528 DTC P0401 thru P0562 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 2529 DTC P0563 thru P0748 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 2530 DTC P0750 thru P0977 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 2531 DTC P0979 thru P1193 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 2532 DTC P1253 thru P1459 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 2533 DTC P1486 thru P1585 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 2534 DTC P1586 thru P1678 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 2535 DTC P1679 thru P1860 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 2536 DTC P1861 thru P2238 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 2537 DTC P2240 thru U0073 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 2538 DTC U0100 thru U1288 Disclaimer Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2539 Engine Control Module: Locations Right Kick Panel Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2542 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2543 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2544 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2545 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2546 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2547 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2548 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2549 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2550 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2551 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2552 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2553 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2554 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2555 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2556 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2557 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2558 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2559 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2560 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2561 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2562 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2563 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2564 Engine Control Module: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2565 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2566 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2567 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2568 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2569 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2570 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2571 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2572 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2573 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2574 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2575 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2576 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2577 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2578 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2579 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2580 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2581 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2582 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2583 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2584 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2585 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2586 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2587 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2588 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2589 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2590 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2591 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 2592 Engine Control Module: Description and Operation PURPOSE The engine control module takes the inputs from the various sensors and signals to manage the fuel injection, timing control and ignition. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics Engine Control Module: Component Tests and General Diagnostics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2595 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2596 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2597 NOTE: When there is no code stored, the MIL will stay on if the service check connector is jumped. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations PGM-FI Main Relay: Locations The PGM-FI relay is located under the left side of the dash. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions PGM-FI Main Relay: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2603 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2604 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2605 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2606 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2607 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2608 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2609 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2610 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2611 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2612 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2613 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2614 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2615 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2616 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2617 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2618 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2619 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2620 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2621 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2622 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2623 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2624 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2625 PGM-FI Main Relay: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2626 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2627 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2628 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2629 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2630 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2631 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2632 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2633 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2634 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2635 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2636 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2637 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2638 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2639 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2640 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2641 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2642 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2643 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2644 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2645 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2646 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2647 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2648 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2649 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2650 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2651 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 2652 PGM-FI Main Relay: Description and Operation PURPOSE/OPERATION The PGM-FI main relay actually contains two individual relays. The relay is located at the left side of the cowl. One relay is energized whenever the ignition is on, which supplies the battery voltage to the ECM, power to the fuel injectors, and power for the second relay. The second relay is energized for 2 seconds when the ignition is switched on, and when the engine is running, to supply power to the fuel pump. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 2653 PGM-FI Main Relay: Testing and Inspection NOTE: If the car starts and continues to run, the PGM-FI main relay is OK. 1. Remove the PGM-FI main relay. 2. Attach the battery positive terminal to the No. 6 terminal and the battery negative terminal to the No. 8 terminal of the PGM-FI main relay. Then check for continuity between the No. 5 terminal and No. 7 terminal of the PGM-FI main relay. ^ If there is continuity, go on to step 3. ^ If there is no continuity, replace the relay and retest. 3. Attach the battery positive terminal to the No. 5 terminal and the battery negative terminal to the No. 2 terminal of the PGM-FI main relay. Then check that there is continuity between the No. 1 terminal and No. 3 terminal of the PGM-FI main relay. ^ If there is continuity, go on to step 4. ^ If there is no continuity, replace the relay and retest. 4. Attach the battery positive terminal to the No. 3 terminal and the battery negative terminal to the No. 8 terminal of the PGM-FI main relay. Then check that there is continuity between the No. 5 terminal and No. 7 terminal of the PGM-FI main relay. ^ If there is continuity, the relay is OK. ^ If there is no continuity, replace the relay and retest. Main Relay And Harness Inspection Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 2654 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 2655 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2662 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2663 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2664 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2665 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2666 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2667 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2668 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2669 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2670 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2671 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2672 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2673 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2674 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2675 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2676 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2677 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2678 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2679 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2680 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2681 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2682 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2683 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2684 Fuel Pump Relay: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2685 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2686 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2687 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2688 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2689 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2690 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2691 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2692 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2693 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2694 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2695 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2696 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2697 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2698 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2699 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2700 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2701 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2702 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2703 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2704 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2705 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2706 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2707 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2708 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2709 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2710 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2711 Fuel Pump Relay: Connector Views For Connector Views refer to "Powertrain Management : Diagrams". Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 2712 Fuel Pump Relay: Description and Operation PURPOSE/OPERATION The Programed Fuel Injection (PGM-FI) Main Relay actually contains two individual Relays. This Relay is located at the left side of the Cowl. One Relay is energized whenever the Ignition is "ON" which supplies the Battery voltage to the Engine Control Module (ECM), power to the Fuel Injectors, and power for the second Relay. The second Relay is energized for two seconds when the Ignition is switched "ON", and when the Engine is running, to supply power to the Fuel Pump. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 2713 Fuel Pump Relay: Testing and Inspection NOTE: If the car starts and continues to run, the PGM-FI main relay is OK. 1. Remove the PGM-FI main relay. 2. Attach the battery positive terminal to the No. 6 terminal and the battery negative terminal to the No. 8 terminal of the PGM-FI main relay. Then check for continuity between the No. 5 terminal and No. 7 terminal of the PGM-FI main relay. - If there is continuity, go on to step 3. - If there is no continuity, replace the relay and retest. 3. Attach the battery positive terminal to the No. 5 terminal and the battery negative terminal to the No. 2 terminal of the PGM-FI main relay. Then check that there is continuity between the No. 1 terminal and No. 3 terminal of the PGM-FI main relay. - If there is continuity, go on to step 4. - If there is no continuity, replace the relay and retest. 4. Attach the battery positive terminal to the No. 3 terminal and the battery negative terminal to the No. 8 terminal of the PGM-FI main relay. Then check that there is continuity between the No. 5 terminal and No. 7 terminal of the PGM-FI main relay. - If there is continuity, the relay is OK. - If there is no continuity, replace the relay and retest. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 2714 FLOWCHART PART 1 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 2715 FLOWCHART PART 2 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations PGM-FI Main Relay: Locations The PGM-FI relay is located under the left side of the dash. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions PGM-FI Main Relay: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2721 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2722 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2723 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2724 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2725 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2726 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2727 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2728 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2729 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2730 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2731 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2732 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2733 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2734 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2735 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2736 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2737 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2738 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2739 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2740 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2741 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2742 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2743 PGM-FI Main Relay: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2744 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2745 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2746 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2747 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2748 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2749 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2750 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2751 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2752 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2753 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2754 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2755 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2756 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2757 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2758 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2759 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2760 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2761 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2762 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2763 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2764 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2765 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2766 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2767 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2768 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2769 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 2770 PGM-FI Main Relay: Description and Operation PURPOSE/OPERATION The PGM-FI main relay actually contains two individual relays. The relay is located at the left side of the cowl. One relay is energized whenever the ignition is on, which supplies the battery voltage to the ECM, power to the fuel injectors, and power for the second relay. The second relay is energized for 2 seconds when the ignition is switched on, and when the engine is running, to supply power to the fuel pump. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 2771 PGM-FI Main Relay: Testing and Inspection NOTE: If the car starts and continues to run, the PGM-FI main relay is OK. 1. Remove the PGM-FI main relay. 2. Attach the battery positive terminal to the No. 6 terminal and the battery negative terminal to the No. 8 terminal of the PGM-FI main relay. Then check for continuity between the No. 5 terminal and No. 7 terminal of the PGM-FI main relay. ^ If there is continuity, go on to step 3. ^ If there is no continuity, replace the relay and retest. 3. Attach the battery positive terminal to the No. 5 terminal and the battery negative terminal to the No. 2 terminal of the PGM-FI main relay. Then check that there is continuity between the No. 1 terminal and No. 3 terminal of the PGM-FI main relay. ^ If there is continuity, go on to step 4. ^ If there is no continuity, replace the relay and retest. 4. Attach the battery positive terminal to the No. 3 terminal and the battery negative terminal to the No. 8 terminal of the PGM-FI main relay. Then check that there is continuity between the No. 5 terminal and No. 7 terminal of the PGM-FI main relay. ^ If there is continuity, the relay is OK. ^ If there is no continuity, replace the relay and retest. Main Relay And Harness Inspection Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 2772 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 2773 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions Ignition Control Module: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2780 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2781 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2782 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2783 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2784 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2785 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2786 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2787 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2788 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2789 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2790 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2791 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2792 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2793 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2794 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2795 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2796 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2797 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2798 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2799 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2800 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2801 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2802 Ignition Control Module: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2803 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2804 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2805 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2806 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2807 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2808 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2809 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2810 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2811 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2812 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2813 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2814 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2815 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2816 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2817 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2818 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2819 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2820 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2821 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2822 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2823 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2824 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2825 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2826 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2827 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2828 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2829 Ignition Control Module: Connector Views For Connector Views refer to "Powertrain Management : Diagrams". Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Page 2830 Ignition Control Module: Testing and Inspection NOTE: Perform an input test for the ignition control module (ICM) after finishing the fundamental tests for the ignition system and the fuel and emissions systems. The tachometer should operate normally. 1. Remove the distributor ignition cap, the distributor ignition rotor, and the leak cover. 2. Disconnect the BLK/YEL, WHT/BLU, YEL/GRN, and BLU wires from the ICM. 3. Turn the ignition switch ON. Check for voltage between the BLK/YEL wire and body ground. There should be battery voltage. ^ If there is no battery voltage, check the BLK/YEL wire between the ignition switch and the ICM. ^ If there is battery voltage, go to step 4. 4. Turn the ignition switch ON. Check for voltage between the WHT/BLU wire and body ground. There should be battery voltage. ^ If there is no battery voltage, check: Ignition coil. - WHT/BLU wire between the ignition coil and the ICM. ^ If there is battery voltage, go to step 5. 5. Check the YEL/GRN wire between the ECM and the ICM. 6. Check the BLU wire between the tachometer and the ICM. 7. If all tests are normal, replace the ICM. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Service and Repair > Removal Ignition Control Module: Service and Repair Removal 1. Disconnect the 2-P and 8-P connectors from the distributor. 2. Disconnect the ignition wires from the distributor ignition cap. 3. Remove the distributor mounting bolts, then remove the distributor from the cylinder bead. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Service and Repair > Removal > Page 2833 Ignition Control Module: Service and Repair Installation 1. Coat a new 0-ring with engine oil, then install it. 2. Slip the distributor into position. NOTE: The lugs on the end of the distributor and its mating grooves in the camshaft end are both offset to eliminate the possibility of installing the distributor 180° out of time. 3. Install the mounting bolts and tighten them temporarily. 4. Connect the 2-P and 8-P connectors to the distributor. 5. Connect the ignition wires as shown. 6. Set the timing with a timing light. 7. After setting the timing, tighten the mounting bolts. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Service and Repair > Removal > Page 2834 Ignition Control Module: Service and Repair Overhaul Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Service and Repair > Removal > Page 2835 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Service and Repair > Removal > Page 2836 Ignition Control Module: Service and Repair Reassembly Reassemble the distributor in the reverse order of disassembly. 1. Install the distributor ignition rotor, then turn it so that it faces in the direction shown (Toward the No. 1 cylinder). 2. Slip the thrust washer and coupling onto the shaft. 3. Check that the distributor ignition rotor is still pointing toward the No. 1 cylinder, then align the index mark on the distributor ignition housing with the index mark on the coupling. 4. Drive in the pin and secure it with the pin retainer. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2843 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2844 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2845 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2846 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2847 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2848 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2849 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2850 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2851 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2852 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2853 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2854 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2855 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2856 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2857 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2858 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2859 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2860 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2861 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2862 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2863 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2864 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2865 Air Flow Meter/Sensor: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2866 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2867 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2868 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2869 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2870 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2871 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2872 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2873 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2874 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2875 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2876 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2877 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2878 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2879 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2880 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2881 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2882 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2883 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2884 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2885 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2886 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2887 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2888 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2889 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2890 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2891 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Description and Operation Barometric Pressure Sensor: Description and Operation PURPOSE Converts barometric pressure to a voltage signal for the engine control module. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation Camshaft Position Sensor: Description and Operation PURPOSE/OPERATION The CKP Sensor determines timing for Fuel Injection and ignition of each Cylinder and also detects Engine speed. The TDC Sensor determines Ignition Timing at start-up (cranking) and when crank angle is abnormal. The CYP Sensor detects the position of No. 1 Cylinder for sequential fuel injection to each Cylinder. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Page 2898 Camshaft Position Sensor: Testing and Inspection Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Page 2899 The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 4: A problem in the Crankshaft Position (CKP) Sensor circuit. The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 8: A problem in the Top Dead Center (TDC) Sensor circuit. The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 9: A problem in the Cylinder Position (CYP) Sensor circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Photo 9 Coolant Temperature Sensor/Switch (For Computer): Locations Photo 9 Right Side Of Engine. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Photo 9 > Page 2904 Coolant Temperature Sensor/Switch (For Computer): Locations Photo 14 Right Front Of Engine. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2905 Coolant Temperature Sensor/Switch (For Computer): Description and Operation PURPOSE/DESCRIPTION The engine coolant temperature sensor is a temperature dependant resistor (thermistor) that convents the engine coolant temperature to voltage and outputs it to the engine control module. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2910 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2911 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2912 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2913 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2914 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2915 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2916 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2917 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2918 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2919 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2920 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2921 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2922 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2923 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2924 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2925 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2926 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2927 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2928 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2929 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2930 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2931 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2932 Crankshaft Position Sensor: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2933 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2934 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2935 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2936 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2937 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2938 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2939 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2940 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2941 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2942 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2943 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2944 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2945 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2946 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2947 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2948 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2949 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2950 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2951 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2952 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2953 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2954 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2955 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2956 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2957 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2958 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 2959 Crankshaft Position Sensor: Testing and Inspection Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 2960 The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 4: A problem in the Crankshaft Position (CKP) Sensor circuit. The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 8: A problem in the Top Dead Center (TDC) Sensor circuit. The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 9: A problem in the Cylinder Position (CYP) Sensor circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Electric Load Sensor > Component Information > Description and Operation Electric Load Sensor: Description and Operation PURPOSE/OPERATION The Electrical Load Detector informs the engine control module of the high electrical draw conditions. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Manifold Pressure/Vacuum Sensor: Locations Middle Of Engine Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2967 Manifold Pressure/Vacuum Sensor: Diagrams For Connector Views refer to "Powertrain Management : Diagrams". Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2968 Manifold Pressure/Vacuum Sensor: Description and Operation PURPOSE The MAP Sensor converts Manifold Absolute Pressure (vacuum) into electrical signals and inputs the Engine Control Module (ECM). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Locations > Photo 4 Heated Oxygen Sensor: Locations Photo 4 Right Front Of Engine Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Locations > Photo 4 > Page 2973 Heated Oxygen Sensor: Locations Photo 5 Right Front Of Engine Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions Heated Oxygen Sensor: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2976 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2977 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2978 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2979 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2980 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2981 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2982 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2983 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2984 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2985 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2986 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2987 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2988 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2989 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2990 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2991 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2992 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2993 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2994 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2995 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2996 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2997 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2998 Heated Oxygen Sensor: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2999 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3000 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3001 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3002 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3003 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3004 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3005 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3006 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3007 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3008 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3009 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3010 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3011 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3012 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3013 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3014 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3015 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3016 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3017 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3018 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3019 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3020 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3021 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3022 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3023 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3024 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Page 3025 Heated Oxygen Sensor: Description and Operation The Oxygen Sensor is mounted to the Exhaust Manifold or pipe with the sensor end extending into the exhaust stream. It uses zirconia and platinum to compare exhaust oxygen content with that of the outside air. When heated by the combination of its internal heater and exhaust gases, the sensor supplies a low voltage signal (0.0 - 1.0 volt) to the ECM. When the engine is running rich, the oxygen differential is relatively high so signal voltage increases. When a lean condition occurs the difference in oxygen content is much lower causing a lower voltage signal to be produced. Oxygen sensor operation is monitored by the Engine Control Module (ECM) and a malfunction should be accompanied by a Diagnostic Trouble Code (DTC). Circuit and output testing procedures are covered in detail in the Diagnostic Trouble Code Charts. See: Computers and Control Systems/Testing and Inspection Oxygen Sensor malfunctions will cause increased emission output and smog check failure. Other symptoms may include poor idle quality or poor fuel economy. HINT: When monitoring oxygen sensor operation with an oscilloscope, watch for a sine wave with a frequency of at least 8 cycles in 10 seconds. A "lazy" oxygen sensor will not always set a code, but will usually cause abnormal emissions levels. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations Power Steering Pressure Switch: Locations Center Rear Of Engine Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 3029 Power Steering Pressure Switch: Diagrams For Connector Views refer to "Powertrain Management : Diagrams". Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 3030 Power Steering Pressure Switch: Description and Operation PURPOSE This signals the Engine Control Module (ECM) when the Power Steering load is high. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 3031 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions Throttle Full Open Switch: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3036 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3037 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3038 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3039 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3040 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3041 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3042 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3043 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3044 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3045 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3046 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3047 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3048 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3049 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3050 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3051 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3052 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3053 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3054 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3055 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3056 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3057 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3058 Throttle Full Open Switch: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3059 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3060 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3061 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3062 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3063 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3064 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3065 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3066 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3067 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3068 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3069 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3070 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3071 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3072 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3073 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3074 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3075 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3076 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3077 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3078 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3079 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3080 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3081 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3082 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3083 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3084 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations Center Rear Of Engine Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3088 Throttle Position Sensor: Diagrams For Connector Views refer to "Powertrain Management : Diagrams". Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3089 Throttle Position Sensor: Description and Operation PURPOSE/OPERATION The TP Sensor is a Potentiometer. It is connected to the Throttle Valve Shaft. As the Throttle Position changes, the Throttle Position Sensor varies the voltage signal to the Engine Control Module (ECM). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > A/T Gear Position Signal <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Locations A/T Gear Position Signal: Locations Below Center Console Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > A/T Gear Position Signal <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Locations > Page 3093 A/T Gear Position Signal: Description and Operation PURPOSE This signals the Engine Control Module (ECM) when the Transmission is in Neutral or Park position. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > A/T Gear Position Signal <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Locations > Page 3094 A/T Gear Position Signal: Testing and Inspection Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > A/T Gear Position Signal <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Locations > Page 3095 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Variable Valve Timing Pressure Switch > Component Information > Diagrams Variable Valve Timing Pressure Switch: Diagrams For Connector Views refer to "Powertrain Management : Diagrams". Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Vehicle Speed Sensor: Locations Right Rear Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3104 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3105 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3106 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3107 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3108 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3109 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3110 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3111 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3112 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3113 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3114 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3115 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3116 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3117 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3118 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3119 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3120 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3121 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3122 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3123 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3124 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3125 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3126 Vehicle Speed Sensor: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3127 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3128 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3129 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3130 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3131 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3132 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3133 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3134 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3135 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3136 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3137 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3138 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3139 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3140 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3141 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3142 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3143 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3144 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3145 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3146 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3147 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3148 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3149 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3150 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3151 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3152 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3153 Vehicle Speed Sensor: Connector Views For Connector Views refer to "Powertrain Management : Diagrams". Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 3154 Vehicle Speed Sensor: Description and Operation With the ignition switch in ON (II) or START (III), battery voltage is supplied from fuse 24 (fuse 12 without SRS) through the BLK/YEL wire to the Vehicle Speed Sensor (VSS). The sensor is grounded by the BLK wire to G101. The speedometer and other control units in the circuit supply about 5 volts to the YEL/WHT wire. The vehicle speed sensor (VSS) intermittently grounds the YEL/WHT wire which generates a pulsed signal in it. The number of pulse per minute increases/decreases with the speed of the car. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 3155 Vehicle Speed Sensor: Testing and Inspection Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 3156 The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 17: A problem in the Vehicle Speed Sensor (VSS) circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3162 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3163 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3164 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3165 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3166 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3167 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3168 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3169 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3170 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3171 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3172 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3173 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3174 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3175 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3176 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3177 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3178 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3179 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3180 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3181 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3182 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3183 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3184 Air Flow Meter/Sensor: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3185 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3186 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3187 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3188 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3189 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3190 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3191 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3192 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3193 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3194 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3195 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3196 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3197 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3198 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3199 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3200 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3201 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3202 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3203 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3204 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3205 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3206 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3207 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3208 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3209 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3210 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions Throttle Full Open Switch: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3215 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3216 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3217 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3218 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3219 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3220 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3221 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3222 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3223 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3224 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3225 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3226 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3227 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3228 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3229 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3230 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3231 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3232 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3233 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3234 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3235 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3236 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3237 Throttle Full Open Switch: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3238 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3239 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3240 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3241 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3242 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3243 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3244 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3245 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3246 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3247 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3248 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3249 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3250 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3251 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3252 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3253 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3254 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3255 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3256 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3257 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3258 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3259 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3260 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3261 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3262 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3263 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations Center Rear Of Engine Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3267 Throttle Position Sensor: Diagrams For Connector Views refer to "Powertrain Management : Diagrams". Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3268 Throttle Position Sensor: Description and Operation PURPOSE/OPERATION The TP Sensor is a Potentiometer. It is connected to the Throttle Valve Shaft. As the Throttle Position changes, the Throttle Position Sensor varies the voltage signal to the Engine Control Module (ECM). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation Camshaft Position Sensor: Description and Operation PURPOSE/OPERATION The CKP Sensor determines timing for Fuel Injection and ignition of each Cylinder and also detects Engine speed. The TDC Sensor determines Ignition Timing at start-up (cranking) and when crank angle is abnormal. The CYP Sensor detects the position of No. 1 Cylinder for sequential fuel injection to each Cylinder. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Page 3273 Camshaft Position Sensor: Testing and Inspection Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Page 3274 The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 4: A problem in the Crankshaft Position (CKP) Sensor circuit. The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 8: A problem in the Top Dead Center (TDC) Sensor circuit. The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 9: A problem in the Cylinder Position (CYP) Sensor circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3279 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3280 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3281 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3282 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3283 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3284 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3285 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3286 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3287 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3288 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3289 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3290 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3291 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3292 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3293 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3294 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3295 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3296 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3297 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3298 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3299 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3300 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3301 Crankshaft Position Sensor: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3302 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3303 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3304 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3305 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3306 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3307 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3308 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3309 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3310 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3311 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3312 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3313 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3314 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3315 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3316 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3317 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3318 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3319 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3320 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3321 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3322 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3323 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3324 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3325 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3326 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3327 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 3328 Crankshaft Position Sensor: Testing and Inspection Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 3329 The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 4: A problem in the Crankshaft Position (CKP) Sensor circuit. The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 8: A problem in the Top Dead Center (TDC) Sensor circuit. The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 9: A problem in the Cylinder Position (CYP) Sensor circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch Ignition Switch Lock Cylinder: Technical Service Bulletins Starting System - Unable To Key In Ignition Switch Can't Turn Ignition Switch? Check for Locked Steering Got a service customer complaining he or she can't turn the ignition switch to start the engine? The reason could just be the steering column lock pin is engaged with the front wheels turned. Here's what typically happens: Some folks use the steering wheel to help support themselves while climbing in or out of the vehicle. This is very common among elderly or disabled drivers. Doing this turns the front wheels, which twists the tires against the ground. The twisted tires apply torque to the steering column. With the ignition switch in LOCK (0), the steering column lock pin is engaged. But the applied torque on the steering column binds the lock pin, making it tough to turn the ignition switch. The ignition switch won't turn to ON (II) if the lock pin isn't disengaged from the steering column. Tell your customer there's nothing wrong with the ignition switch itself. All he or she needs to do is turn the steering wheel from side to side while turning the switch. This usually releases the lock pin so the engine can be started. In some cases, though, your customer may need to give a good tug on the wheel. This could easily happen when parking on a hill and the wheels are turned sharply before the engine is shut off. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > Tools - New Fuel Pressure Gauge and Replacement Parts Fuel Pressure: Technical Service Bulletins Tools - New Fuel Pressure Gauge and Replacement Parts 97-020 MAR 10, 1997 Applies To: ALL Models New Fuel Pressure Gauge and Replacement Parts New Gauge The fuel pressure gauge with 10" hose (T/N 07406-0040001) has been discontinued. The gauge that replaces it (T/N 07406-004000A) has an easier-to-read face, a protective boot around the gauge housing, and a 48" hose. Replacement Parts Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > Tools - New Fuel Pressure Gauge and Replacement Parts > Page 3340 The replacement hose for the old gauge (24", T/N 07406-004020A) has also been discontinued. If you need a replacement hose, order the new 48" hose (T/N 07406-004020B). The new hose comes with an adapter so you can use it with the old fuel pressure gauge (T/N 07406-0040001). Before connecting the hose to the vehicle, make sure the aluminum washer on the end of the hose seals properly. If the aluminum washer doesn't seal, replace the washer. Replacement washers come in a set of five (T/N 07406-0040300). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > Page 3341 Fuel Pressure: Specifications At Curb Idle With Vacuum Hose Connected ....................................................................................................................................................... 215-265 kPa (31-38 psi) With Vacuum Hose Disconnected ................................................................................................................................................... 280-330 kPa (40-47 psi) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > Page 3342 Fuel Pressure: Testing and Inspection 1. Relieve fuel pressure. 2. Remove the service bolt on the fuel filter while holding the banjo bolt with another wrench. Attach the special tool. 3. Start the engine *. Measure the fuel pressure with the engine idling and vacuum hose of the fuel pressure regulator disconnected from the fuel pressure regulator and pinched. Pressure should be: 280-330 kPa (2.8-3.3 kg/cm2, 40-47 psi) 4. Reconnect vacuum hose to the fuel pressure regulator. Pressure should be: 215-265 kPa (2.15-2.65 kg/cm2, 31-38 psi) ^ If the engine will not start, turn the ignition switch on, wait for two seconds, turn it off, then back on again and read the fuel pressure. ^ If the fuel pressure is not as specified, first check the fuel pump. If the fuel is OK, check the following: ^ If the fuel pressure is higher than specified, inspect for: Pinched or clogged fuel return hose or piping. - Faulty fuel pressure regulator. ^ If the fuel pressure is lower than specified, inspect for: Clogged fuel filter. - Faulty fuel pressure regulator. Leakage in the fuel hoses or pipes. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Adjustments Air/Fuel Mixture: Adjustments The Air/Fuel mixture is controlled by the engine control module and is not adjustable. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications IDLE SPEED Manual transmission ............................................................................................................................ ................................................. 670 RPM [01] Automatic transmission .............................................. ........................................................................................................................... 670 RPM [01] [01] -- Transmission in Neutral or Park, headlights and cooling fan OFF. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 3349 Idle Speed: Testing and Inspection 1. Start the engine and allow it to warm-up (the radiator fan comes on). 2. Connect a tachometer to the test tachometer connector. NOTE: All electrical systems should be turned OFF. IDLE SPEED: (M/T) in neutral: (USA): 670 ± 50 rpm (Canada): 750 ± 50 rpm (A/T) in [N] or [P]: (USA): 700 ± 50 rpm (Canada): 750 ± 50 rpm 3. Adjust the idle speed, if necessary. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 3350 Idle Speed: Adjustments NOTE: ^ When the idle speed set, check the following items: The MIL has not been reported on. - Ignition timing - Spark plugs - Air cleaner - PCV system ^ (Canada) Pull the parking brake lever up. Start the engine, then check that the headlights are off. 1. Start the engine. Hold the engine at 3,000 rpm with no load (A/T in [N] or [P] position, M/T in neutral) until the radiator fan comes on, then let it idle. 2. Connect a tachometer. 3. Disconnect the 2P connector from the Idle Air Control (IAC) valve. 4. Start the engine with the accelerator pedal slightly depressed. Stabilize the rpm at 1,000, then slowly release the pedal until the engine idles. 5. Check idling in no-load conditions: headlights, blower fan, rear defogger, radiator fan, and air conditioning are not operating. Idle speed should be: M/T D15Z1 engine: 420 +/- 50 rpm Others: 420 +/- 50 rpm A/T 420 +/- 50 rpm (in [N] or [P] position) Adjust the idle speed, if necessary, by turning the idle adjusting screw. NOTE: After adjusting the idle speed in this step, check the ignition timing. If it is out of spec, go back to step 4. 6. Turn the ignition switch OFF. 7. Reconnect the 2P connector on the IAC valve, then remove BACK UP (7.5 A) fuse in the under-hood fuse/relay box for 10 seconds to reset the ECM. 8. Restart and idle the engine with no-load conditions for one minute, then check the idle speed. NOTE: (Canada) Pull the parking brake lever up. Start the engine, then check that the headlights are off. Idle speed should be: Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 3351 M/T D15Z1 engine: 600 +/- 50 rpm Others: 670 +/- 50 rpm A/T 700 +/- 50 rpm (in [N] or [P] position) 9. Idle the engine for one minute with headlights (Low) ON and check the idle speed. Idle speed should be: M/T D15Z1 engine: 700 +/- 50 rpm Others: 750 +/- 50 rpm A/T 750 +/- 50 rpm (in [N] or [P] position) 10. Turn the headlights off. Idle the engine for one minute with heater fan switch at HI and air conditioner on, then check the idle speed. Idle speed should be: M/T D15Z1 engine: 810 +/- 50 rpm Others: 810 +/- 50 rpm A/T 810 +/- 50 rpm (in [N] or [P] position) NOTE: If the idle speed is not within specification, see System Troubleshooting Guide. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component Information > Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair WARNING: Do not smoke while working on the Fuel system. Keep open flames or sparks away from your work area. Be sure to relieve fuel pressure while the Ignition Switch is off. NOTE: Before disconnecting fuel pipes or hoses, release pressure from the system by loosening the 6 mm service bolt on top of the fuel filter. 1. Disconnect the battery negative cable from the battery negative terminal. 2. Remove the fuel fill cap. 3. Use a box end wrench on the 6 mm service bolt at the fuel filter, while holding the special banjo bolt with another wrench. 4. Place a rag or shop towel over the 6 mm service bolt. 5. Slowly loosen the 6 mm service bolt one complete turn. NOTE: A fuel pressure gauge can be attached at the 6 mm service bolt hole. - Always replace the washer between the service bolt and the special banjo bolt whenever the service bolt is loosened. - Replace all washers whenever the bolts are removed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > System Check Connector <--> [Ignition Timing Connector] > Component Information > Locations > Component Locations System Check Connector: Component Locations The Service Check Connector is located behind the glove box. CAUTION: Do not use a jumper wire on the Data Link Connector. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > System Check Connector <--> [Ignition Timing Connector] > Component Information > Locations > Component Locations > Page 3367 System Check Connector: Connector Locations The Service Check Connector is located behind the glove box. CAUTION: Do not use a jumper wire on the Data Link Connector. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Timing Marks and Indicators > System Information > Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications Resistance at 20°C (68°F) ................................................................................................................... ......................................................... 25 K Ohms max Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions Ignition Cable: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3379 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3380 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3381 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3382 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3383 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3384 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3385 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3386 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3387 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3388 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3389 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3390 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3391 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3392 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3393 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3394 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3395 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3396 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3397 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3398 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3399 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3400 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3401 Ignition Cable: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3402 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3403 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3404 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3405 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3406 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3407 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3408 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3409 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3410 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3411 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3412 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3413 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3414 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3415 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3416 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3417 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3418 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3419 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3420 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3421 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3422 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3423 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3424 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3425 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3426 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3427 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Page 3428 Ignition Cable: Testing and Inspection CAUTION: Carefully remove the ignition wires by pulling on the rubber boots. Do not bend the wires; you might break them inside. 1. Check the condition of the wire terminals. If any terminal is corroded, clean it, and if it is broken or distorted, replace the wire. 2. Connect ohmmeter probes and measure resistance. Resistance: 25 k Ohms max. at 70° F (20°C) 3. If resistance exceeds 25 k Ohms, replace the ignition wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Cap > Component Information > Testing and Inspection Distributor Cap: Testing and Inspection Check the following points, repair or replace as needed if a problem is found. 1. There must be no cracking in the cap. 2. There must be no damage to the cap's electrodes. 3. Clean away any accumulated dirt from the cap. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Testing and Inspection Ignition Rotor: Testing and Inspection Check the following points, repair or replace as needed if a problem is found. 1. There must be no cracking in the rotor. 2. There must be no damage to the rotor's electrode. 3. Clean away any accumulated dirt from the rotor. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap and Torque Spark Plug: Specifications Gap and Torque Spark Plug Gap ................................................................................................................................... ........................................................ 1.1 mm (0.043 in) Spark Plug Torque ............................................................................................................................... ......................................................... 18 Nm (13 ft lb) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap and Torque > Page 3440 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3441 Spark Plug: Testing and Inspection Spark Plug Inspection 1. Inspect the electrodes and ceramic insulator for: Burned or worn electrodes may be caused by: ^ Advanced ignition timing ^ Loose spark plug ^ Plug heat range too low ^ Insufficient cooling Fouled plug may be caused by: ^ Retarded ignition timing ^ Oil in combustion chamber ^ Incorrect spark plug gap ^ Plug heat range too high ^ Excessive idling/low speed running ^ Clogged air cleaner element ^ Deteriorated ignition coil or ignition wires 2. Adjust the gap with a suitable gapping tool. 3. Replace the plug if the center electrode is rounded as shown above. NOTE: Do not use spark plugs other than recommended types. These plugs are a new type (ISO standard). 4. Screw the plugs into the cylinder head finger tight, then torque them to 18 N-m (1.8 kg-m, 13 lb-ft). NOTE: Apply a small quantity of anti-seize compound to the plug threads before installing. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Check compression with engine at normal operating temperature and throttle in wide open position. Prior to performing test, disable ignition and fuel injection to prevent fuel from being sprayed into cylinders while cranking engine. Ensure is fully charged and that cranking speed is 250 RPM. Standard reading should be 135-184 psi. The maximum variation between cylinders is 28 psi. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications Valve Clearance Intake ................................................................................................................................................... .......................................... 0.007-0.009 inches Exhaust ................................................................................................................................................ .......................................... 0.009-0.011 inches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 3448 Valve Clearance: Adjustments VALVE CLEARANCE ADJUSTMENT NOTE: Valves should be adjusted only when the cylinder head temperature is less than 100°F (38°C). Adjustment is the same for intake and exhaust valves. ^ After adjusting, Retorque the crankshaft pulley bolt to 181 Nm (134 ft. lbs.). 1. Remove the cylinder head cover. 2. Set the No. 1 piston at TDC. "UP" mark on the camshaft pulley should be at top, and TDC marks should align with the cylinder head surface. The crankshaft pulley should be at TDC. 3. Adjust valves on No. 1 cylinder. - Intake: 0.18-0.22 mm (0.007-0.009 inch) - Exhaust: 0.23-0.27 mm (0.009-0.011 inch) 4. Loosen the locknut, and turn the adjustment screw until the feeler gauge slides back and forth with a slight amount of drag. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 3449 CAUTION: Do not overtighten the locknuts; the rocker arms are made of aluminum. 5. Tighten the locknut, and check the clearance again. Repeat the adjustment if necessary. 6. Rotate the crankshaft 180° counterclockwise (camshaft pulley turns 90°). The "UP" mark should be on the exhaust side. Adjust valves on No. 3 cylinder. 7. Rotate the crankshaft 180° counterclockwise to bring No. 4 piston to TDC. Both TDC grooves are once again visible. Adjust valves on No. 4 cylinder. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 3450 8. Rotate the crankshaft 180° counterclockwise to bring No. 2 piston to TDC. The UP" mark should be on the intake side. Adjust valves on No. 2 cylinder. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Description and Operation A/C Signal: Description and Operation PURPOSE This signals the ECM when there is a demand for cooling from the air conditioning system. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Description and Operation > Page 3455 A/C Signal: Testing and Inspection Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Description and Operation > Page 3456 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3461 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3462 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3463 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3464 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3465 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3466 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3467 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3468 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3469 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3470 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3471 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3472 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3473 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3474 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3475 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3476 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3477 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3478 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3479 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3480 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3481 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3482 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3483 Air Flow Meter/Sensor: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3484 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3485 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3486 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3487 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3488 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3489 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3490 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3491 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3492 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3493 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3494 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3495 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3496 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3497 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3498 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3499 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3500 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3501 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3502 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3503 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3504 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3505 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3506 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3507 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3508 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3509 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Description and Operation Auxiliary Air Valve (Idle Speed): Description and Operation To prevent erratic running when the engine is warming up, it is necessary to raise the idle speed. The fast idle thermo valve is controlled by a thermowax plunger. When the engine is cold, the engine coolant surrounding the thermowax contracts the plunger, allowing additional air to be bypassed into the intake manifold so that the engine idles faster. When the engine reaches operating temperature, the valve closes, reducing the amount of air bypassing into the manifold. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Description and Operation > Page 3513 Auxiliary Air Valve (Idle Speed): Testing and Inspection NOTE: The fast idle thermo valve is factory adjusted; it should not be disassembled. 1. Remove the intake air duct from the throttle body. 2. Start the engine. 3. Put your finger over the lower port in throttle body and make sure that there is air flow with the engine cold (engine coolant temperature below 86° F, (30°C)). ^ If not, replace the fast idle thermo valve and retest. 4. Warm up the engine (the radiator fan comes on). 5. Check that the valve is completely closed. If not, air suction can be felt at the lower port in the throttle body. ^ If any suction is felt, the valve is leaking. Check engine coolant level and for air in the engine coolant system. If OK, replace the fast idle thermo valve and recheck. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Barometric Pressure Sensor > Component Information > Description and Operation Barometric Pressure Sensor: Description and Operation PURPOSE Converts barometric pressure to a voltage signal for the engine control module. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Locations Body Control Module: Locations Rear Of Under-dash Fuse/Relay Box Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3522 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3523 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3524 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3525 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3526 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3527 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3528 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3529 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3530 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3531 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3532 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3533 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3534 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3535 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3536 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3537 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3538 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3539 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3540 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3541 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3542 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3543 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3544 Body Control Module: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3545 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3546 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3547 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3548 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3549 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3550 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3551 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3552 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3553 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3554 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3555 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3556 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3557 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3558 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3559 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3560 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3561 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3562 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3563 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3564 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3565 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3566 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3567 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3568 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3569 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3570 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Switch Signal <--> [Brake Signal] > Component Information > Description and Operation Brake Switch Signal: Description and Operation PURPOSE/OPERATION This signals the Engine Control Module (ECM) when the Brake Pedal is depressed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Switch Signal <--> [Brake Signal] > Component Information > Description and Operation > Page 3574 Brake Switch Signal: Testing and Inspection Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation Camshaft Position Sensor: Description and Operation PURPOSE/OPERATION The CKP Sensor determines timing for Fuel Injection and ignition of each Cylinder and also detects Engine speed. The TDC Sensor determines Ignition Timing at start-up (cranking) and when crank angle is abnormal. The CYP Sensor detects the position of No. 1 Cylinder for sequential fuel injection to each Cylinder. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Page 3578 Camshaft Position Sensor: Testing and Inspection Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Page 3579 The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 4: A problem in the Crankshaft Position (CKP) Sensor circuit. The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 8: A problem in the Top Dead Center (TDC) Sensor circuit. The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 9: A problem in the Cylinder Position (CYP) Sensor circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Photo 9 Coolant Temperature Sensor/Switch (For Computer): Locations Photo 9 Right Side Of Engine. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Photo 9 > Page 3584 Coolant Temperature Sensor/Switch (For Computer): Locations Photo 14 Right Front Of Engine. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3585 Coolant Temperature Sensor/Switch (For Computer): Description and Operation PURPOSE/DESCRIPTION The engine coolant temperature sensor is a temperature dependant resistor (thermistor) that convents the engine coolant temperature to voltage and outputs it to the engine control module. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Starter Switch Signal <--> [Cranking Signal] > Component Information > Description and Operation Starter Switch Signal: Description and Operation PURPOSE This signals the Engine Control Module (ECM) when the Engine is cranking. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Starter Switch Signal <--> [Cranking Signal] > Component Information > Description and Operation > Page 3589 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3594 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3595 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3596 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3597 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3598 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3599 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3600 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3601 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3602 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3603 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3604 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3605 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3606 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3607 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3608 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3609 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3610 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3611 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3612 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3613 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3614 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3615 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3616 Crankshaft Position Sensor: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3617 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3618 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3619 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3620 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3621 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3622 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3623 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3624 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3625 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3626 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3627 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3628 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3629 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3630 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3631 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3632 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3633 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3634 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3635 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3636 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3637 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3638 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3639 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3640 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3641 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3642 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 3643 Crankshaft Position Sensor: Testing and Inspection Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 3644 The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 4: A problem in the Crankshaft Position (CKP) Sensor circuit. The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 8: A problem in the Top Dead Center (TDC) Sensor circuit. The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 9: A problem in the Cylinder Position (CYP) Sensor circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Photo View Data Link Connector: Locations Photo View Right Kick Panel Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Photo View > Page 3649 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions Data Link Connector: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3652 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3653 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3654 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3655 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3656 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3657 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3658 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3659 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3660 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3661 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3662 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3663 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3664 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3665 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3666 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3667 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3668 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3669 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3670 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3671 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3672 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3673 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3674 Data Link Connector: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3675 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3676 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3677 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3678 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3679 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3680 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3681 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3682 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3683 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3684 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3685 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3686 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3687 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3688 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3689 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3690 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3691 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3692 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3693 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3694 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3695 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3696 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3697 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3698 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3699 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3700 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Electric Load Sensor > Component Information > Description and Operation Electric Load Sensor: Description and Operation PURPOSE/OPERATION The Electrical Load Detector informs the engine control module of the high electrical draw conditions. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors Engine Control Module: Technical Service Bulletins Emissions - OBD II DTC's And Associated Monitors 03-020 April 2, 2010 Applies To: All OBD II-equipped models except Passport OBD II DTCs and Their Associated Monitors (Supersedes 03-020, dated March 29, 2003, to revise the information marked by the black bars and asterisks) *REVISION SUMMARY Numerous DTCs were added. Refer to the list for details.* Following is a list of all OBD II DTCs and their associated monitors for all Honda automobiles with OBD II. No one model has every DTC in the list. DTC P0AA6 thru P0A9E Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 3708 DTC P0A94 thru P0157 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 3709 DTC P0158 thru P0400 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 3710 DTC P0401 thru P0562 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 3711 DTC P0563 thru P0748 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 3712 DTC P0750 thru P0977 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 3713 DTC P0979 thru P1193 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 3714 DTC P1253 thru P1459 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 3715 DTC P1486 thru P1585 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 3716 DTC P1586 thru P1678 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 3717 DTC P1679 thru P1860 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 3718 DTC P1861 thru P2238 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 3719 DTC P2240 thru U0073 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 3720 DTC U0100 thru U1288 Disclaimer Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3721 Engine Control Module: Locations Right Kick Panel Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3724 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3725 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3726 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3727 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3728 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3729 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3730 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3731 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3732 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3733 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3734 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3735 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3736 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3737 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3738 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3739 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3740 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3741 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3742 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3743 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3744 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3745 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3746 Engine Control Module: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3747 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3748 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3749 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3750 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3751 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3752 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3753 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3754 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3755 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3756 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3757 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3758 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3759 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3760 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3761 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3762 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3763 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3764 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3765 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3766 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3767 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3768 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3769 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3770 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3771 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3772 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3773 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 3774 Engine Control Module: Description and Operation PURPOSE The engine control module takes the inputs from the various sensors and signals to manage the fuel injection, timing control and ignition. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics Engine Control Module: Component Tests and General Diagnostics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 3777 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 3778 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 3779 NOTE: When there is no code stored, the MIL will stay on if the service check connector is jumped. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Locations Idle Speed/Throttle Actuator - Electronic: Locations Center Rear Of Engine Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions Idle Speed/Throttle Actuator - Electronic: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3785 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3786 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3787 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3788 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3789 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3790 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3791 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3792 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3793 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3794 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3795 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3796 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3797 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3798 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3799 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3800 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3801 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3802 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3803 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3804 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3805 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3806 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3807 Idle Speed/Throttle Actuator - Electronic: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3808 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3809 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3810 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3811 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3812 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3813 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3814 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3815 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3816 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3817 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3818 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3819 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3820 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3821 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3822 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3823 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3824 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3825 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3826 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3827 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3828 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3829 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3830 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3831 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3832 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3833 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 3834 Idle Speed/Throttle Actuator - Electronic: Description and Operation PURPOSE The IAC Valve changes the amount of air bypassing the Throttle Body in response to a current signal from the Engine Control Module (ECM) in order to maintain the proper idle speed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 3835 Idle Speed/Throttle Actuator - Electronic: Testing and Inspection Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 3836 The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 14: A problem in the Idle Air Control (IAC) Valve circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Ignition Output Signal > Component Information > Description and Operation Ignition Output Signal: Description and Operation PURPOSE/OPERATION The Ignition Output Signal informs the engine control module of ignition system operation. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Ignition Output Signal > Component Information > Description and Operation > Page 3840 Ignition Output Signal: Testing and Inspection Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Ignition Output Signal > Component Information > Description and Operation > Page 3841 The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 15: A problem in the Ignition Output Signal circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions Information Bus: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3846 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3847 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3848 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3849 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3850 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3851 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3852 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3853 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3854 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3855 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3856 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3857 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3858 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3859 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3860 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3861 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3862 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3863 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3864 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3865 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3866 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3867 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3868 Information Bus: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3869 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3870 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3871 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3872 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3873 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3874 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3875 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3876 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3877 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3878 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3879 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3880 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3881 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3882 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3883 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3884 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3885 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3886 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3887 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3888 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3889 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3890 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3891 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3892 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3893 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3894 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations PGM-FI Main Relay: Locations The PGM-FI relay is located under the left side of the dash. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions PGM-FI Main Relay: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3900 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3901 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3902 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3903 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3904 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3905 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3906 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3907 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3908 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3909 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3910 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3911 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3912 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3913 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3914 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3915 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3916 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3917 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3918 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3919 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3920 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3921 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3922 PGM-FI Main Relay: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3923 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3924 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3925 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3926 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3927 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3928 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3929 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3930 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3931 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3932 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3933 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3934 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3935 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3936 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3937 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3938 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3939 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3940 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3941 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3942 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3943 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3944 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3945 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3946 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3947 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3948 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 3949 PGM-FI Main Relay: Description and Operation PURPOSE/OPERATION The PGM-FI main relay actually contains two individual relays. The relay is located at the left side of the cowl. One relay is energized whenever the ignition is on, which supplies the battery voltage to the ECM, power to the fuel injectors, and power for the second relay. The second relay is energized for 2 seconds when the ignition is switched on, and when the engine is running, to supply power to the fuel pump. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 3950 PGM-FI Main Relay: Testing and Inspection NOTE: If the car starts and continues to run, the PGM-FI main relay is OK. 1. Remove the PGM-FI main relay. 2. Attach the battery positive terminal to the No. 6 terminal and the battery negative terminal to the No. 8 terminal of the PGM-FI main relay. Then check for continuity between the No. 5 terminal and No. 7 terminal of the PGM-FI main relay. ^ If there is continuity, go on to step 3. ^ If there is no continuity, replace the relay and retest. 3. Attach the battery positive terminal to the No. 5 terminal and the battery negative terminal to the No. 2 terminal of the PGM-FI main relay. Then check that there is continuity between the No. 1 terminal and No. 3 terminal of the PGM-FI main relay. ^ If there is continuity, go on to step 4. ^ If there is no continuity, replace the relay and retest. 4. Attach the battery positive terminal to the No. 3 terminal and the battery negative terminal to the No. 8 terminal of the PGM-FI main relay. Then check that there is continuity between the No. 5 terminal and No. 7 terminal of the PGM-FI main relay. ^ If there is continuity, the relay is OK. ^ If there is no continuity, replace the relay and retest. Main Relay And Harness Inspection Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 3951 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 3952 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Locations > Page 3956 Malfunction Indicator Lamp: Testing and Inspection When the Malfunction Indicator Lamp (MIL) has been reported on, do the following: 1. Connect the Service Check Connector terminals with a jumper wire as shown. (The 2P Service Check Connector is located under the dash on the passenger side of the car.) Turn the ignition switch on. 2. Note the Diagnostic Trouble Code (DTC): The MIL indicates a code by the length and number of blinks. The MIL can indicate simultaneous component problems by blinking separate codes, one after another. Codes I through 9 are indicated by individual short blinks. Codes 10 through 48 are indicated by a series of long and short blinks. The number of long blinks equals the first digit, the number of Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Manifold Pressure/Vacuum Sensor: Locations Middle Of Engine Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3960 Manifold Pressure/Vacuum Sensor: Diagrams For Connector Views refer to "Powertrain Management : Diagrams". Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3961 Manifold Pressure/Vacuum Sensor: Description and Operation PURPOSE The MAP Sensor converts Manifold Absolute Pressure (vacuum) into electrical signals and inputs the Engine Control Module (ECM). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Locations > Photo 4 Heated Oxygen Sensor: Locations Photo 4 Right Front Of Engine Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Locations > Photo 4 > Page 3966 Heated Oxygen Sensor: Locations Photo 5 Right Front Of Engine Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions Heated Oxygen Sensor: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3969 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3970 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3971 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3972 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3973 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3974 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3975 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3976 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3977 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3978 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3979 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3980 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3981 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3982 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3983 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3984 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3985 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3986 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3987 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3988 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3989 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3990 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3991 Heated Oxygen Sensor: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3992 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3993 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3994 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3995 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3996 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3997 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3998 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3999 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4000 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4001 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4002 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4003 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4004 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4005 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4006 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4007 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4008 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4009 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4010 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4011 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4012 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4013 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4014 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4015 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4016 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4017 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Page 4018 Heated Oxygen Sensor: Description and Operation The Oxygen Sensor is mounted to the Exhaust Manifold or pipe with the sensor end extending into the exhaust stream. It uses zirconia and platinum to compare exhaust oxygen content with that of the outside air. When heated by the combination of its internal heater and exhaust gases, the sensor supplies a low voltage signal (0.0 - 1.0 volt) to the ECM. When the engine is running rich, the oxygen differential is relatively high so signal voltage increases. When a lean condition occurs the difference in oxygen content is much lower causing a lower voltage signal to be produced. Oxygen sensor operation is monitored by the Engine Control Module (ECM) and a malfunction should be accompanied by a Diagnostic Trouble Code (DTC). Circuit and output testing procedures are covered in detail in the Diagnostic Trouble Code Charts. See: Testing and Inspection Oxygen Sensor malfunctions will cause increased emission output and smog check failure. Other symptoms may include poor idle quality or poor fuel economy. HINT: When monitoring oxygen sensor operation with an oscilloscope, watch for a sine wave with a frequency of at least 8 cycles in 10 seconds. A "lazy" oxygen sensor will not always set a code, but will usually cause abnormal emissions levels. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations Power Steering Pressure Switch: Locations Center Rear Of Engine Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 4022 Power Steering Pressure Switch: Diagrams For Connector Views refer to "Powertrain Management : Diagrams". Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 4023 Power Steering Pressure Switch: Description and Operation PURPOSE This signals the Engine Control Module (ECM) when the Power Steering load is high. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 4024 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations Body Control Module: Locations Rear Of Under-dash Fuse/Relay Box Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4031 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4032 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4033 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4034 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4035 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4036 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4037 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4038 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4039 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4040 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4041 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4042 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4043 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4044 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4045 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4046 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4047 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4048 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4049 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4050 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4051 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4052 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4053 Body Control Module: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4054 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4055 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4056 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4057 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4058 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4059 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4060 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4061 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4062 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4063 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4064 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4065 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4066 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4067 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4068 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4069 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4070 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4071 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4072 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4073 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4074 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4075 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4076 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4077 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4078 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4079 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors Engine Control Module: Technical Service Bulletins Emissions - OBD II DTC's And Associated Monitors 03-020 April 2, 2010 Applies To: All OBD II-equipped models except Passport OBD II DTCs and Their Associated Monitors (Supersedes 03-020, dated March 29, 2003, to revise the information marked by the black bars and asterisks) *REVISION SUMMARY Numerous DTCs were added. Refer to the list for details.* Following is a list of all OBD II DTCs and their associated monitors for all Honda automobiles with OBD II. No one model has every DTC in the list. DTC P0AA6 thru P0A9E Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 4084 DTC P0A94 thru P0157 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 4085 DTC P0158 thru P0400 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 4086 DTC P0401 thru P0562 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 4087 DTC P0563 thru P0748 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 4088 DTC P0750 thru P0977 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 4089 DTC P0979 thru P1193 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 4090 DTC P1253 thru P1459 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 4091 DTC P1486 thru P1585 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 4092 DTC P1586 thru P1678 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 4093 DTC P1679 thru P1860 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 4094 DTC P1861 thru P2238 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 4095 DTC P2240 thru U0073 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 4096 DTC U0100 thru U1288 Disclaimer Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4097 Engine Control Module: Locations Right Kick Panel Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4100 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4101 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4102 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4103 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4104 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4105 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4106 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4107 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4108 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4109 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4110 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4111 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4112 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4113 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4114 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4115 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4116 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4117 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4118 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4119 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4120 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4121 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4122 Engine Control Module: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4123 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4124 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4125 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4126 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4127 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4128 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4129 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4130 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4131 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4132 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4133 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4134 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4135 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4136 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4137 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4138 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4139 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4140 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4141 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4142 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4143 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4144 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4145 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4146 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4147 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4148 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4149 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 4150 Engine Control Module: Description and Operation PURPOSE The engine control module takes the inputs from the various sensors and signals to manage the fuel injection, timing control and ignition. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics Engine Control Module: Component Tests and General Diagnostics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 4153 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 4154 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 4155 NOTE: When there is no code stored, the MIL will stay on if the service check connector is jumped. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations PGM-FI Main Relay: Locations The PGM-FI relay is located under the left side of the dash. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions PGM-FI Main Relay: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4161 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4162 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4163 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4164 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4165 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4166 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4167 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4168 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4169 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4170 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4171 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4172 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4173 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4174 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4175 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4176 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4177 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4178 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4179 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4180 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4181 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4182 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4183 PGM-FI Main Relay: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4184 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4185 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4186 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4187 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4188 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4189 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4190 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4191 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4192 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4193 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4194 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4195 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4196 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4197 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4198 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4199 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4200 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4201 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4202 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4203 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4204 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4205 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4206 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4207 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4208 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 4209 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 4210 PGM-FI Main Relay: Description and Operation PURPOSE/OPERATION The PGM-FI main relay actually contains two individual relays. The relay is located at the left side of the cowl. One relay is energized whenever the ignition is on, which supplies the battery voltage to the ECM, power to the fuel injectors, and power for the second relay. The second relay is energized for 2 seconds when the ignition is switched on, and when the engine is running, to supply power to the fuel pump. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 4211 PGM-FI Main Relay: Testing and Inspection NOTE: If the car starts and continues to run, the PGM-FI main relay is OK. 1. Remove the PGM-FI main relay. 2. Attach the battery positive terminal to the No. 6 terminal and the battery negative terminal to the No. 8 terminal of the PGM-FI main relay. Then check for continuity between the No. 5 terminal and No. 7 terminal of the PGM-FI main relay. ^ If there is continuity, go on to step 3. ^ If there is no continuity, replace the relay and retest. 3. Attach the battery positive terminal to the No. 5 terminal and the battery negative terminal to the No. 2 terminal of the PGM-FI main relay. Then check that there is continuity between the No. 1 terminal and No. 3 terminal of the PGM-FI main relay. ^ If there is continuity, go on to step 4. ^ If there is no continuity, replace the relay and retest. 4. Attach the battery positive terminal to the No. 3 terminal and the battery negative terminal to the No. 8 terminal of the PGM-FI main relay. Then check that there is continuity between the No. 5 terminal and No. 7 terminal of the PGM-FI main relay. ^ If there is continuity, the relay is OK. ^ If there is no continuity, replace the relay and retest. Main Relay And Harness Inspection Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 4212 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 4213 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4219 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4220 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4221 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4222 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4223 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4224 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4225 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4226 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4227 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4228 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4229 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4230 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4231 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4232 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4233 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4234 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4235 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4236 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4237 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4238 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4239 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4240 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4241 Air Flow Meter/Sensor: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4242 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4243 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4244 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4245 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4246 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4247 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4248 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4249 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4250 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4251 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4252 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4253 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4254 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4255 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4256 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4257 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4258 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4259 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4260 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4261 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4262 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4263 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4264 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4265 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4266 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4267 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Barometric Pressure Sensor > Component Information > Description and Operation Barometric Pressure Sensor: Description and Operation PURPOSE Converts barometric pressure to a voltage signal for the engine control module. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation Camshaft Position Sensor: Description and Operation PURPOSE/OPERATION The CKP Sensor determines timing for Fuel Injection and ignition of each Cylinder and also detects Engine speed. The TDC Sensor determines Ignition Timing at start-up (cranking) and when crank angle is abnormal. The CYP Sensor detects the position of No. 1 Cylinder for sequential fuel injection to each Cylinder. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Page 4274 Camshaft Position Sensor: Testing and Inspection Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Page 4275 The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 4: A problem in the Crankshaft Position (CKP) Sensor circuit. The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 8: A problem in the Top Dead Center (TDC) Sensor circuit. The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 9: A problem in the Cylinder Position (CYP) Sensor circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Photo 9 Coolant Temperature Sensor/Switch (For Computer): Locations Photo 9 Right Side Of Engine. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Photo 9 > Page 4280 Coolant Temperature Sensor/Switch (For Computer): Locations Photo 14 Right Front Of Engine. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 4281 Coolant Temperature Sensor/Switch (For Computer): Description and Operation PURPOSE/DESCRIPTION The engine coolant temperature sensor is a temperature dependant resistor (thermistor) that convents the engine coolant temperature to voltage and outputs it to the engine control module. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4286 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4287 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4288 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4289 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4290 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4291 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4292 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4293 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4294 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4295 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4296 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4297 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4298 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4299 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4300 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4301 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4302 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4303 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4304 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4305 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4306 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4307 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4308 Crankshaft Position Sensor: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4309 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4310 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4311 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4312 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4313 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4314 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4315 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4316 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4317 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4318 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4319 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4320 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4321 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4322 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4323 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4324 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4325 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4326 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4327 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4328 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4329 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4330 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4331 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4332 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4333 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4334 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 4335 Crankshaft Position Sensor: Testing and Inspection Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 4336 The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 4: A problem in the Crankshaft Position (CKP) Sensor circuit. The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 8: A problem in the Top Dead Center (TDC) Sensor circuit. The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 9: A problem in the Cylinder Position (CYP) Sensor circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Electric Load Sensor > Component Information > Description and Operation Electric Load Sensor: Description and Operation PURPOSE/OPERATION The Electrical Load Detector informs the engine control module of the high electrical draw conditions. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Manifold Pressure/Vacuum Sensor: Locations Middle Of Engine Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 4343 Manifold Pressure/Vacuum Sensor: Diagrams For Connector Views refer to "Powertrain Management : Diagrams". Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 4344 Manifold Pressure/Vacuum Sensor: Description and Operation PURPOSE The MAP Sensor converts Manifold Absolute Pressure (vacuum) into electrical signals and inputs the Engine Control Module (ECM). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Locations > Photo 4 Heated Oxygen Sensor: Locations Photo 4 Right Front Of Engine Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Locations > Photo 4 > Page 4349 Heated Oxygen Sensor: Locations Photo 5 Right Front Of Engine Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions Heated Oxygen Sensor: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4352 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4353 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4354 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4355 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4356 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4357 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4358 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4359 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4360 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4361 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4362 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4363 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4364 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4365 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4366 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4367 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4368 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4369 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4370 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4371 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4372 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4373 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4374 Heated Oxygen Sensor: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4375 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4376 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4377 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4378 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4379 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4380 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4381 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4382 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4383 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4384 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4385 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4386 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4387 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4388 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4389 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4390 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4391 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4392 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4393 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4394 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4395 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4396 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4397 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4398 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4399 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4400 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Page 4401 Heated Oxygen Sensor: Description and Operation The Oxygen Sensor is mounted to the Exhaust Manifold or pipe with the sensor end extending into the exhaust stream. It uses zirconia and platinum to compare exhaust oxygen content with that of the outside air. When heated by the combination of its internal heater and exhaust gases, the sensor supplies a low voltage signal (0.0 - 1.0 volt) to the ECM. When the engine is running rich, the oxygen differential is relatively high so signal voltage increases. When a lean condition occurs the difference in oxygen content is much lower causing a lower voltage signal to be produced. Oxygen sensor operation is monitored by the Engine Control Module (ECM) and a malfunction should be accompanied by a Diagnostic Trouble Code (DTC). Circuit and output testing procedures are covered in detail in the Diagnostic Trouble Code Charts. See: Testing and Inspection Oxygen Sensor malfunctions will cause increased emission output and smog check failure. Other symptoms may include poor idle quality or poor fuel economy. HINT: When monitoring oxygen sensor operation with an oscilloscope, watch for a sine wave with a frequency of at least 8 cycles in 10 seconds. A "lazy" oxygen sensor will not always set a code, but will usually cause abnormal emissions levels. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations Power Steering Pressure Switch: Locations Center Rear Of Engine Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 4405 Power Steering Pressure Switch: Diagrams For Connector Views refer to "Powertrain Management : Diagrams". Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 4406 Power Steering Pressure Switch: Description and Operation PURPOSE This signals the Engine Control Module (ECM) when the Power Steering load is high. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 4407 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions Throttle Full Open Switch: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4412 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4413 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4414 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4415 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4416 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4417 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4418 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4419 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4420 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4421 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4422 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4423 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4424 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4425 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4426 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4427 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4428 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4429 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4430 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4431 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4432 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4433 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4434 Throttle Full Open Switch: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4435 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4436 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4437 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4438 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4439 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4440 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4441 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4442 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4443 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4444 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4445 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4446 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4447 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4448 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4449 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4450 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4451 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4452 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4453 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4454 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4455 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4456 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4457 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4458 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4459 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4460 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations Center Rear Of Engine Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 4464 Throttle Position Sensor: Diagrams For Connector Views refer to "Powertrain Management : Diagrams". Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 4465 Throttle Position Sensor: Description and Operation PURPOSE/OPERATION The TP Sensor is a Potentiometer. It is connected to the Throttle Valve Shaft. As the Throttle Position changes, the Throttle Position Sensor varies the voltage signal to the Engine Control Module (ECM). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > A/T Gear Position Signal <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Locations A/T Gear Position Signal: Locations Below Center Console Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > A/T Gear Position Signal <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Locations > Page 4469 A/T Gear Position Signal: Description and Operation PURPOSE This signals the Engine Control Module (ECM) when the Transmission is in Neutral or Park position. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > A/T Gear Position Signal <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Locations > Page 4470 A/T Gear Position Signal: Testing and Inspection Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > A/T Gear Position Signal <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Locations > Page 4471 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Variable Valve Timing Pressure Switch > Component Information > Diagrams Variable Valve Timing Pressure Switch: Diagrams For Connector Views refer to "Powertrain Management : Diagrams". Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Vehicle Speed Sensor: Locations Right Rear Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4480 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4481 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4482 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4483 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4484 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4485 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4486 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4487 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4488 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4489 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4490 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4491 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4492 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4493 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4494 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4495 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4496 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4497 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4498 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4499 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4500 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4501 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4502 Vehicle Speed Sensor: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4503 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4504 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4505 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4506 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4507 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4508 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4509 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4510 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4511 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4512 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4513 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4514 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4515 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4516 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4517 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4518 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4519 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4520 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4521 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4522 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4523 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4524 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4525 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4526 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4527 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4528 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4529 Vehicle Speed Sensor: Connector Views For Connector Views refer to "Powertrain Management : Diagrams". Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 4530 Vehicle Speed Sensor: Description and Operation With the ignition switch in ON (II) or START (III), battery voltage is supplied from fuse 24 (fuse 12 without SRS) through the BLK/YEL wire to the Vehicle Speed Sensor (VSS). The sensor is grounded by the BLK wire to G101. The speedometer and other control units in the circuit supply about 5 volts to the YEL/WHT wire. The vehicle speed sensor (VSS) intermittently grounds the YEL/WHT wire which generates a pulsed signal in it. The number of pulse per minute increases/decreases with the speed of the car. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 4531 Vehicle Speed Sensor: Testing and Inspection Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 4532 The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 17: A problem in the Vehicle Speed Sensor (VSS) circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions Throttle Full Open Switch: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4537 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4538 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4539 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4540 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4541 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4542 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4543 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4544 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4545 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4546 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4547 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4548 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4549 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4550 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4551 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4552 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4553 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4554 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4555 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4556 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4557 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4558 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4559 Throttle Full Open Switch: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4560 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4561 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4562 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4563 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4564 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4565 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4566 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4567 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4568 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4569 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4570 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4571 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4572 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4573 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4574 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4575 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4576 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4577 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4578 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4579 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4580 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4581 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4582 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4583 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4584 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4585 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations Center Rear Of Engine Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 4589 Throttle Position Sensor: Diagrams For Connector Views refer to "Powertrain Management : Diagrams". Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 4590 Throttle Position Sensor: Description and Operation PURPOSE/OPERATION The TP Sensor is a Potentiometer. It is connected to the Throttle Valve Shaft. As the Throttle Position changes, the Throttle Position Sensor varies the voltage signal to the Engine Control Module (ECM). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > A/T Gear Position Signal <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Locations A/T Gear Position Signal: Locations Below Center Console Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > A/T Gear Position Signal <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Locations > Page 4594 A/T Gear Position Signal: Description and Operation PURPOSE This signals the Engine Control Module (ECM) when the Transmission is in Neutral or Park position. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > A/T Gear Position Signal <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Locations > Page 4595 A/T Gear Position Signal: Testing and Inspection Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > A/T Gear Position Signal <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Locations > Page 4596 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions Variable Valve Timing Actuator: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 4601 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 4602 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 4603 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 4604 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 4605 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 4606 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 4607 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 4608 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 4609 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 4610 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 4611 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 4612 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 4613 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 4614 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 4615 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 4616 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 4617 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 4618 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 4619 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 4620 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 4621 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 4622 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 4623 Variable Valve Timing Actuator: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 4624 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 4625 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 4626 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 4627 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 4628 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 4629 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 4630 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 4631 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 4632 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 4633 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 4634 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 4635 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 4636 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 4637 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 4638 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 4639 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 4640 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 4641 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 4642 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 4643 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 4644 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 4645 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 4646 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 4647 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 4648 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 4649 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Pressure Switch > Component Information > Diagrams Variable Valve Timing Pressure Switch: Diagrams For Connector Views refer to "Powertrain Management : Diagrams". Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Vehicle Speed Sensor: Locations Right Rear Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4658 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4659 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4660 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4661 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4662 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4663 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4664 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4665 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4666 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4667 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4668 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4669 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4670 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4671 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4672 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4673 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4674 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4675 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4676 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4677 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4678 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4679 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4680 Vehicle Speed Sensor: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4681 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4682 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4683 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4684 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4685 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4686 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4687 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4688 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4689 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4690 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4691 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4692 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4693 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4694 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4695 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4696 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4697 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4698 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4699 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4700 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4701 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4702 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4703 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4704 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4705 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4706 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4707 Vehicle Speed Sensor: Connector Views For Connector Views refer to "Powertrain Management : Diagrams". Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 4708 Vehicle Speed Sensor: Description and Operation With the ignition switch in ON (II) or START (III), battery voltage is supplied from fuse 24 (fuse 12 without SRS) through the BLK/YEL wire to the Vehicle Speed Sensor (VSS). The sensor is grounded by the BLK wire to G101. The speedometer and other control units in the circuit supply about 5 volts to the YEL/WHT wire. The vehicle speed sensor (VSS) intermittently grounds the YEL/WHT wire which generates a pulsed signal in it. The number of pulse per minute increases/decreases with the speed of the car. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 4709 Vehicle Speed Sensor: Testing and Inspection Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 4710 The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 17: A problem in the Vehicle Speed Sensor (VSS) circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Alternator FR Signal <--> [Voltage Signal] > Component Information > Description and Operation Alternator FR Signal: Description and Operation PURPOSE This signals the Engine Control Module (ECM) when the Alternator is charging. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Alternator FR Signal <--> [Voltage Signal] > Component Information > Description and Operation > Page 4714 Alternator FR Signal: Testing and Inspection Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Alternator FR Signal <--> [Voltage Signal] > Component Information > Description and Operation > Page 4715 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Three Way Catalytic (TWC) Converter <--> [Catalytic Converter] > Component Information > Technical Service Bulletins > Exhaust System - Catalytic Converter Noise Three Way Catalytic (TWC) Converter: Technical Service Bulletins Exhaust System - Catalytic Converter Noise SOURCE: Honda Service News TITLE: Catalytic Converter Noise? Check the Heat Shield APPLIES TO: All models SERVICE TIP: Got a vehicle in your shop that buzzes or rattles, and you suspect the catalytic converter is the culprit? Before you start replacing the converter, first check the heat shield area. If there any stones or debris trapped inside, they can cause buzzing or rattling. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Three Way Catalytic (TWC) Converter <--> [Catalytic Converter] > Component Information > Technical Service Bulletins > Page 4721 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Three Way Catalytic (TWC) Converter <--> [Catalytic Converter] > Component Information > Technical Service Bulletins > Page 4722 Three Way Catalytic (TWC) Converter: Description and Operation PURPOSE/OPERATION The Three Way Catalytic Converter (TWC) is used to convert Hydrocarbons (HC), Carbon Monoxide (CO), and Oxides of Nitrogen (NOx) in the exhaust gas, to Carbon Dioxide (CO2), Dinitrogen (N2) and water vapor. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Three Way Catalytic (TWC) Converter <--> [Catalytic Converter] > Component Information > Technical Service Bulletins > Page 4723 Three Way Catalytic (TWC) Converter: Testing and Inspection INSPECTION If excessive exhaust system back-pressure is suspected, remove the TWC from the car and make a visual check for plugging, melting or cracking of the Catalyst. Replace the TWC if any of the visible area is damaged or plugged. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Locations Canister Purge Control Valve: Locations Middle Of Engine Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations Canister Purge Solenoid: Locations Middle Of Engine Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions Canister Purge Solenoid: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4733 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4734 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4735 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4736 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4737 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4738 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4739 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4740 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4741 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4742 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4743 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4744 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4745 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4746 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4747 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4748 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4749 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4750 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4751 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4752 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4753 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4754 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4755 Canister Purge Solenoid: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4756 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4757 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4758 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4759 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4760 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4761 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4762 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4763 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4764 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4765 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4766 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4767 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4768 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4769 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4770 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4771 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4772 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4773 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4774 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4775 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4776 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4777 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4778 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4779 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4780 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4781 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Two-Way Valve <--> [Evaporative Check Valve] > Component Information > Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Two-Way Valve <--> [Evaporative Check Valve] > Component Information > Locations > Page 4785 Two-Way Valve: Testing and Inspection 1. Remove the fuel fill cap. 2. Remove vapor line from the fuel tank and connect to T-fitting from vacuum gauge and vacuum pump as shown. 3. Apply vacuum slowly and continuously while watching the gauge. Vacuum should stabilize momentarily at 5 to 15 mmHg (0.2 to 0.6 in. Hg). ^ If vacuum stabilizes (valve opens) below 5 mmHg (0.2 in. Hg) or above 15 mmHg (0.6 in. Hg), in stall new valve and retest. 4. Move vacuum pump hose from vacuum to pressure fitting, and move vacuum gauge hose from vacuum to pressure side as shown. 5. Slowly pressurize the vapor line while watching the gauge. Pressure should stabilize at 10 to 35 mmHg (0.4 to 1.4 in. Hg). ^ If pressure momentarily stabilizes (valve opens) at 10 to 35 mmHg (0.4 to 1.4 in. Hg). the valve is 0K. ^ If pressure stabilizes below 10 mmHg (0.4 in. Hg) or above 35 mmHg (1.4 in. Hg), install a new valve and retest. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Diagrams > Diagram Information and Instructions Evaporative Emission Control Canister: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Diagrams > Diagram Information and Instructions > Page 4791 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Diagrams > Diagram Information and Instructions > Page 4792 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Diagrams > Diagram Information and Instructions > Page 4793 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Diagrams > Diagram Information and Instructions > Page 4794 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Diagrams > Diagram Information and Instructions > Page 4795 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Diagrams > Diagram Information and Instructions > Page 4796 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Diagrams > Diagram Information and Instructions > Page 4797 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Diagrams > Diagram Information and Instructions > Page 4798 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Diagrams > Diagram Information and Instructions > Page 4799 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Diagrams > Diagram Information and Instructions > Page 4800 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Diagrams > Diagram Information and Instructions > Page 4801 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Diagrams > Diagram Information and Instructions > Page 4802 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Diagrams > Diagram Information and Instructions > Page 4803 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Diagrams > Diagram Information and Instructions > Page 4804 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Diagrams > Diagram Information and Instructions > Page 4805 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Diagrams > Diagram Information and Instructions > Page 4806 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Diagrams > Diagram Information and Instructions > Page 4807 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Diagrams > Diagram Information and Instructions > Page 4808 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Diagrams > Diagram Information and Instructions > Page 4809 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Diagrams > Diagram Information and Instructions > Page 4810 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Diagrams > Diagram Information and Instructions > Page 4811 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Diagrams > Diagram Information and Instructions > Page 4812 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Diagrams > Diagram Information and Instructions > Page 4813 Evaporative Emission Control Canister: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Diagrams > Diagram Information and Instructions > Page 4814 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Diagrams > Diagram Information and Instructions > Page 4815 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Diagrams > Diagram Information and Instructions > Page 4816 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Diagrams > Diagram Information and Instructions > Page 4817 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Diagrams > Diagram Information and Instructions > Page 4818 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Diagrams > Diagram Information and Instructions > Page 4819 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Diagrams > Diagram Information and Instructions > Page 4820 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Diagrams > Diagram Information and Instructions > Page 4821 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Diagrams > Diagram Information and Instructions > Page 4822 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Diagrams > Diagram Information and Instructions > Page 4823 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Diagrams > Diagram Information and Instructions > Page 4824 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Diagrams > Diagram Information and Instructions > Page 4825 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Diagrams > Diagram Information and Instructions > Page 4826 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Diagrams > Diagram Information and Instructions > Page 4827 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Diagrams > Diagram Information and Instructions > Page 4828 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Diagrams > Diagram Information and Instructions > Page 4829 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Diagrams > Diagram Information and Instructions > Page 4830 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Diagrams > Diagram Information and Instructions > Page 4831 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Diagrams > Diagram Information and Instructions > Page 4832 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Diagrams > Diagram Information and Instructions > Page 4833 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Diagrams > Diagram Information and Instructions > Page 4834 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Diagrams > Diagram Information and Instructions > Page 4835 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Diagrams > Diagram Information and Instructions > Page 4836 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Diagrams > Diagram Information and Instructions > Page 4837 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Diagrams > Diagram Information and Instructions > Page 4838 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Diagrams > Diagram Information and Instructions > Page 4839 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Diagrams > Page 4840 Evaporative Emission Control Canister: Description and Operation EVAPORATIVE EMISSION (EVAP) CONTROL CANISTER EVAP Control Canister is used for the temporary storage of fuel vapor until the fuel vapor can be purged from the EVAP Control Canister into the engine and burned. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Diagrams > Diagram Information and Instructions Exhaust Gas Recirculation: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Diagrams > Diagram Information and Instructions > Page 4845 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Diagrams > Diagram Information and Instructions > Page 4846 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Diagrams > Diagram Information and Instructions > Page 4847 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Diagrams > Diagram Information and Instructions > Page 4848 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Diagrams > Diagram Information and Instructions > Page 4849 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Diagrams > Diagram Information and Instructions > Page 4850 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Diagrams > Diagram Information and Instructions > Page 4851 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Diagrams > Diagram Information and Instructions > Page 4852 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Diagrams > Diagram Information and Instructions > Page 4853 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Diagrams > Diagram Information and Instructions > Page 4854 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Diagrams > Diagram Information and Instructions > Page 4855 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Diagrams > Diagram Information and Instructions > Page 4856 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Diagrams > Diagram Information and Instructions > Page 4857 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Diagrams > Diagram Information and Instructions > Page 4858 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Diagrams > Diagram Information and Instructions > Page 4859 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Diagrams > Diagram Information and Instructions > Page 4860 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Diagrams > Diagram Information and Instructions > Page 4861 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Diagrams > Diagram Information and Instructions > Page 4862 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Diagrams > Diagram Information and Instructions > Page 4863 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Diagrams > Diagram Information and Instructions > Page 4864 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Diagrams > Diagram Information and Instructions > Page 4865 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Diagrams > Diagram Information and Instructions > Page 4866 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Diagrams > Diagram Information and Instructions > Page 4867 Exhaust Gas Recirculation: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Diagrams > Diagram Information and Instructions > Page 4868 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Diagrams > Diagram Information and Instructions > Page 4869 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Diagrams > Diagram Information and Instructions > Page 4870 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Diagrams > Diagram Information and Instructions > Page 4871 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Diagrams > Diagram Information and Instructions > Page 4872 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Diagrams > Diagram Information and Instructions > Page 4873 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Diagrams > Diagram Information and Instructions > Page 4874 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Diagrams > Diagram Information and Instructions > Page 4875 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Diagrams > Diagram Information and Instructions > Page 4876 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Diagrams > Diagram Information and Instructions > Page 4877 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Diagrams > Diagram Information and Instructions > Page 4878 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Diagrams > Diagram Information and Instructions > Page 4879 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Diagrams > Diagram Information and Instructions > Page 4880 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Diagrams > Diagram Information and Instructions > Page 4881 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Diagrams > Diagram Information and Instructions > Page 4882 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Diagrams > Diagram Information and Instructions > Page 4883 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Diagrams > Diagram Information and Instructions > Page 4884 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Diagrams > Diagram Information and Instructions > Page 4885 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Diagrams > Diagram Information and Instructions > Page 4886 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Diagrams > Diagram Information and Instructions > Page 4887 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Diagrams > Diagram Information and Instructions > Page 4888 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Diagrams > Diagram Information and Instructions > Page 4889 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Diagrams > Diagram Information and Instructions > Page 4890 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Diagrams > Diagram Information and Instructions > Page 4891 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Diagrams > Diagram Information and Instructions > Page 4892 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Diagrams > Diagram Information and Instructions > Page 4893 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Technical Service Bulletins > Tools - New Fuel Pressure Gauge and Replacement Parts Fuel Pressure: Technical Service Bulletins Tools - New Fuel Pressure Gauge and Replacement Parts 97-020 MAR 10, 1997 Applies To: ALL Models New Fuel Pressure Gauge and Replacement Parts New Gauge The fuel pressure gauge with 10" hose (T/N 07406-0040001) has been discontinued. The gauge that replaces it (T/N 07406-004000A) has an easier-to-read face, a protective boot around the gauge housing, and a 48" hose. Replacement Parts Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Technical Service Bulletins > Tools - New Fuel Pressure Gauge and Replacement Parts > Page 4903 The replacement hose for the old gauge (24", T/N 07406-004020A) has also been discontinued. If you need a replacement hose, order the new 48" hose (T/N 07406-004020B). The new hose comes with an adapter so you can use it with the old fuel pressure gauge (T/N 07406-0040001). Before connecting the hose to the vehicle, make sure the aluminum washer on the end of the hose seals properly. If the aluminum washer doesn't seal, replace the washer. Replacement washers come in a set of five (T/N 07406-0040300). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Technical Service Bulletins > Page 4904 Fuel Pressure: Specifications At Curb Idle With Vacuum Hose Connected ....................................................................................................................................................... 215-265 kPa (31-38 psi) With Vacuum Hose Disconnected ................................................................................................................................................... 280-330 kPa (40-47 psi) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Technical Service Bulletins > Page 4905 Fuel Pressure: Testing and Inspection 1. Relieve fuel pressure. 2. Remove the service bolt on the fuel filter while holding the banjo bolt with another wrench. Attach the special tool. 3. Start the engine *. Measure the fuel pressure with the engine idling and vacuum hose of the fuel pressure regulator disconnected from the fuel pressure regulator and pinched. Pressure should be: 280-330 kPa (2.8-3.3 kg/cm2, 40-47 psi) 4. Reconnect vacuum hose to the fuel pressure regulator. Pressure should be: 215-265 kPa (2.15-2.65 kg/cm2, 31-38 psi) ^ If the engine will not start, turn the ignition switch on, wait for two seconds, turn it off, then back on again and read the fuel pressure. ^ If the fuel pressure is not as specified, first check the fuel pump. If the fuel is OK, check the following: ^ If the fuel pressure is higher than specified, inspect for: Pinched or clogged fuel return hose or piping. - Faulty fuel pressure regulator. ^ If the fuel pressure is lower than specified, inspect for: Clogged fuel filter. - Faulty fuel pressure regulator. Leakage in the fuel hoses or pipes. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair WARNING: Do not smoke while working on the Fuel system. Keep open flames or sparks away from your work area. Be sure to relieve fuel pressure while the Ignition Switch is off. NOTE: Before disconnecting fuel pipes or hoses, release pressure from the system by loosening the 6 mm service bolt on top of the fuel filter. 1. Disconnect the battery negative cable from the battery negative terminal. 2. Remove the fuel fill cap. 3. Use a box end wrench on the 6 mm service bolt at the fuel filter, while holding the special banjo bolt with another wrench. 4. Place a rag or shop towel over the 6 mm service bolt. 5. Slowly loosen the 6 mm service bolt one complete turn. NOTE: A fuel pressure gauge can be attached at the 6 mm service bolt hole. - Always replace the washer between the service bolt and the special banjo bolt whenever the service bolt is loosened. - Replace all washers whenever the bolts are removed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications Idle Speed: Specifications IDLE SPEED Manual transmission ............................................................................................................................ ................................................. 670 RPM [01] Automatic transmission .............................................. ........................................................................................................................... 670 RPM [01] [01] -- Transmission in Neutral or Park, headlights and cooling fan OFF. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications > Page 4912 Idle Speed: Testing and Inspection 1. Start the engine and allow it to warm-up (the radiator fan comes on). 2. Connect a tachometer to the test tachometer connector. NOTE: All electrical systems should be turned OFF. IDLE SPEED: (M/T) in neutral: (USA): 670 ± 50 rpm (Canada): 750 ± 50 rpm (A/T) in [N] or [P]: (USA): 700 ± 50 rpm (Canada): 750 ± 50 rpm 3. Adjust the idle speed, if necessary. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications > Page 4913 Idle Speed: Adjustments NOTE: ^ When the idle speed set, check the following items: The MIL has not been reported on. - Ignition timing - Spark plugs - Air cleaner - PCV system ^ (Canada) Pull the parking brake lever up. Start the engine, then check that the headlights are off. 1. Start the engine. Hold the engine at 3,000 rpm with no load (A/T in [N] or [P] position, M/T in neutral) until the radiator fan comes on, then let it idle. 2. Connect a tachometer. 3. Disconnect the 2P connector from the Idle Air Control (IAC) valve. 4. Start the engine with the accelerator pedal slightly depressed. Stabilize the rpm at 1,000, then slowly release the pedal until the engine idles. 5. Check idling in no-load conditions: headlights, blower fan, rear defogger, radiator fan, and air conditioning are not operating. Idle speed should be: M/T D15Z1 engine: 420 +/- 50 rpm Others: 420 +/- 50 rpm A/T 420 +/- 50 rpm (in [N] or [P] position) Adjust the idle speed, if necessary, by turning the idle adjusting screw. NOTE: After adjusting the idle speed in this step, check the ignition timing. If it is out of spec, go back to step 4. 6. Turn the ignition switch OFF. 7. Reconnect the 2P connector on the IAC valve, then remove BACK UP (7.5 A) fuse in the under-hood fuse/relay box for 10 seconds to reset the ECM. 8. Restart and idle the engine with no-load conditions for one minute, then check the idle speed. NOTE: (Canada) Pull the parking brake lever up. Start the engine, then check that the headlights are off. Idle speed should be: Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications > Page 4914 M/T D15Z1 engine: 600 +/- 50 rpm Others: 670 +/- 50 rpm A/T 700 +/- 50 rpm (in [N] or [P] position) 9. Idle the engine for one minute with headlights (Low) ON and check the idle speed. Idle speed should be: M/T D15Z1 engine: 700 +/- 50 rpm Others: 750 +/- 50 rpm A/T 750 +/- 50 rpm (in [N] or [P] position) 10. Turn the headlights off. Idle the engine for one minute with heater fan switch at HI and air conditioner on, then check the idle speed. Idle speed should be: M/T D15Z1 engine: 810 +/- 50 rpm Others: 810 +/- 50 rpm A/T 810 +/- 50 rpm (in [N] or [P] position) NOTE: If the idle speed is not within specification, see System Troubleshooting Guide. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System Information > Adjustments Air/Fuel Mixture: Adjustments The Air/Fuel mixture is controlled by the engine control module and is not adjustable. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Component Information > Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4925 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4926 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4927 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4928 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4929 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4930 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4931 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4932 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4933 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4934 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4935 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4936 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4937 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4938 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4939 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4940 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4941 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4942 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4943 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4944 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4945 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4946 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4947 Air Flow Meter/Sensor: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4948 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4949 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4950 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4951 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4952 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4953 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4954 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4955 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4956 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4957 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4958 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4959 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4960 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4961 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4962 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4963 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4964 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4965 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4966 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4967 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4968 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4969 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4970 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4971 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4972 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4973 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Description and Operation Auxiliary Air Valve (Idle Speed): Description and Operation To prevent erratic running when the engine is warming up, it is necessary to raise the idle speed. The fast idle thermo valve is controlled by a thermowax plunger. When the engine is cold, the engine coolant surrounding the thermowax contracts the plunger, allowing additional air to be bypassed into the intake manifold so that the engine idles faster. When the engine reaches operating temperature, the valve closes, reducing the amount of air bypassing into the manifold. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Description and Operation > Page 4977 Auxiliary Air Valve (Idle Speed): Testing and Inspection NOTE: The fast idle thermo valve is factory adjusted; it should not be disassembled. 1. Remove the intake air duct from the throttle body. 2. Start the engine. 3. Put your finger over the lower port in throttle body and make sure that there is air flow with the engine cold (engine coolant temperature below 86° F, (30°C)). ^ If not, replace the fast idle thermo valve and retest. 4. Warm up the engine (the radiator fan comes on). 5. Check that the valve is completely closed. If not, air suction can be felt at the lower port in the throttle body. ^ If any suction is felt, the valve is leaking. Check engine coolant level and for air in the engine coolant system. If OK, replace the fast idle thermo valve and recheck. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair WARNING: Do not smoke while working on the Fuel system. Keep open flames or sparks away from your work area. Be sure to relieve fuel pressure while the Ignition Switch is off. NOTE: Before disconnecting fuel pipes or hoses, release pressure from the system by loosening the 6 mm service bolt on top of the fuel filter. 1. Disconnect the battery negative cable from the battery negative terminal. 2. Remove the fuel fill cap. 3. Use a box end wrench on the 6 mm service bolt at the fuel filter, while holding the special banjo bolt with another wrench. 4. Place a rag or shop towel over the 6 mm service bolt. 5. Slowly loosen the 6 mm service bolt one complete turn. NOTE: A fuel pressure gauge can be attached at the 6 mm service bolt hole. - Always replace the washer between the service bolt and the special banjo bolt whenever the service bolt is loosened. - Replace all washers whenever the bolts are removed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions Fuel Injector: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4987 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4988 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4989 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4990 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4991 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4992 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4993 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4994 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4995 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4996 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4997 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4998 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4999 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5000 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5001 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5002 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5003 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5004 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5005 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5006 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5007 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5008 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5009 Fuel Injector: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5010 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5011 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5012 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5013 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5014 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5015 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5016 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5017 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5018 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5019 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5020 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5021 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5022 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5023 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5024 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5025 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5026 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5027 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5028 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5029 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5030 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5031 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5032 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5033 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5034 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5035 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Page 5036 Fuel Injector: Description and Operation PURPOSE/OPERATION The Fuel Injectors are a Solenoid-Actuated constant-stroke Pintle type consisting of a Solenoid, Plunger Needle Valve and Housing. When current is applied to the Solenoid Coil, the Valve lifts up and pressurized fuel is injected. Because the Needle Valve lift and the fuel pressure are constant, the injection quantity is determined by the length of time that the Valve is open (i.e., the duration the current is supplied to the Solenoid Coil). The Fuel Injector is sealed by an 0-ring and Seal Ring at the top and bottom. These Seals also reduce operating noise. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Page 5037 Fuel Injector: Service and Repair WARNING: Do not smoke when working on the fuel system. Keep open flames away from your work area. 1. Relieve the fuel pressure. 2. Disconnect the connectors from the fuel injectors. 3. Disconnect the vacuum hose and fuel return hose from the fuel pressure regulator. NOTE: Place a rag or shop towel over the hoses before disconnecting them. 4. Disconnect the fuel pulsation damper and fuel hose from the fuel rail. 5. Loosen the retainer nuts on the fuel rail and harness holder. 6. Disconnect the fuel rail. 7. Remove the fuel injectors from the intake manifold. 8. Slide new cushion rings onto the fuel injectors. 9. Coat new 0-rings with clean engine oil and put them on the fuel injectors. 10. Insert the fuel injectors into the fuel rail first. 11. Coat new seal rings with clean engine oil and press them into the intake manifold. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Page 5038 12. Install the fuel injectors and fuel rail assembly in the intake manifold. CAUTION: To prevent damage to the 0-rings, install the fuel injectors in the fuel rail first, then install them in the intake manifold. 13. Align the center line on the connector with the mark on the fuel rail. (D15Z1 engine only) 14. Install and tighten the retainer nuts. 15. Connect the fuel hose and fuel pulsation damper to the fuel rail with new washers. 16. Connect the vacuum hose and fuel return hose to the fuel pressure regulator. 17. Install the connectors on the fuel injectors. 18. Turn the ignition switch ON, but do not operate the starter. After the fuel pump runs for approximately two seconds, the fuel pressure in the fuel line rises. Repeat this two or three times, then check whether there is any fuel leakage. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions Fuel Pressure Control Solenoid: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 5043 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 5044 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 5045 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 5046 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 5047 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 5048 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 5049 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 5050 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 5051 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 5052 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 5053 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 5054 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 5055 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 5056 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 5057 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 5058 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 5059 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 5060 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 5061 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 5062 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 5063 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 5064 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 5065 Fuel Pressure Control Solenoid: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 5066 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 5067 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 5068 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 5069 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 5070 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 5071 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 5072 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 5073 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 5074 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 5075 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 5076 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 5077 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 5078 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 5079 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 5080 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 5081 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 5082 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 5083 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 5084 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 5085 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 5086 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 5087 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 5088 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 5089 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 5090 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 5091 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 5092 Fuel Pressure Control Solenoid: Connector Views For Connector Views refer to "Powertrain Management : Diagrams". Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Page 5096 Fuel Pressure Regulator: Description and Operation The fuel pressure regulator maintains a constant fuel pressure to the fuel injectors. When the difference between the fuel pressure and manifold pressure exceeds 300 kPa (3.0 kg/cm2, 43 psi), the diaphragm is pushed upward, and the excess fuel is fed back into the fuel tank through the return line. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Page 5097 Fuel Pressure Regulator: Testing and Inspection WARNING: Do not smoke during the test. Keep open flames away from your work area. 1. Attach a fuel pressure gauge to the service port of the fuel filter. Pressure should be: 280-330 kPa (2.8-3.3 kg/cm2, 40-47 psi) (with the fuel pressure regulator vacuum hose disconnected and pinched) 2. Reconnect the vacuum hose to the fuel pressure regulator. 3. Check that the fuel pressure rises when the vacuum hose from the fuel pressure regulator is disconnected again. NOTE: If the fuel pressure did not rise, replace the fuel pressure regulator. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Page 5098 Fuel Pressure Regulator: Service and Repair WARNING: DO NOT SMOKE WHILE WORKING ON FUEL SYSTEM. KEEP OPEN FLAME AWAY FROM YOUR WORK AREA. 1. Place a shop towel under fuel pressure regulator, then relieve fuel pressure. 2. Disconnect the vacuum hose and fuel return hose. 3. Remove the two 6 mm mounting bolts. NOTE: Replace the 0-ring. - When assembling the fuel pressure regulator, apply clean engine oil to the 0-ring and assemble it into its proper position, taking care not to damage the 0-ring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper > Component Information > Locations Fuel And Emissions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Technical Service Bulletins > Tools - New Fuel Pressure Gauge and Replacement Parts Fuel Pressure: Technical Service Bulletins Tools - New Fuel Pressure Gauge and Replacement Parts 97-020 MAR 10, 1997 Applies To: ALL Models New Fuel Pressure Gauge and Replacement Parts New Gauge The fuel pressure gauge with 10" hose (T/N 07406-0040001) has been discontinued. The gauge that replaces it (T/N 07406-004000A) has an easier-to-read face, a protective boot around the gauge housing, and a 48" hose. Replacement Parts Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Technical Service Bulletins > Tools - New Fuel Pressure Gauge and Replacement Parts > Page 5107 The replacement hose for the old gauge (24", T/N 07406-004020A) has also been discontinued. If you need a replacement hose, order the new 48" hose (T/N 07406-004020B). The new hose comes with an adapter so you can use it with the old fuel pressure gauge (T/N 07406-0040001). Before connecting the hose to the vehicle, make sure the aluminum washer on the end of the hose seals properly. If the aluminum washer doesn't seal, replace the washer. Replacement washers come in a set of five (T/N 07406-0040300). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Technical Service Bulletins > Page 5108 Fuel Pressure: Specifications At Curb Idle With Vacuum Hose Connected ....................................................................................................................................................... 215-265 kPa (31-38 psi) With Vacuum Hose Disconnected ................................................................................................................................................... 280-330 kPa (40-47 psi) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Technical Service Bulletins > Page 5109 Fuel Pressure: Testing and Inspection 1. Relieve fuel pressure. 2. Remove the service bolt on the fuel filter while holding the banjo bolt with another wrench. Attach the special tool. 3. Start the engine *. Measure the fuel pressure with the engine idling and vacuum hose of the fuel pressure regulator disconnected from the fuel pressure regulator and pinched. Pressure should be: 280-330 kPa (2.8-3.3 kg/cm2, 40-47 psi) 4. Reconnect vacuum hose to the fuel pressure regulator. Pressure should be: 215-265 kPa (2.15-2.65 kg/cm2, 31-38 psi) ^ If the engine will not start, turn the ignition switch on, wait for two seconds, turn it off, then back on again and read the fuel pressure. ^ If the fuel pressure is not as specified, first check the fuel pump. If the fuel is OK, check the following: ^ If the fuel pressure is higher than specified, inspect for: Pinched or clogged fuel return hose or piping. - Faulty fuel pressure regulator. ^ If the fuel pressure is lower than specified, inspect for: Clogged fuel filter. - Faulty fuel pressure regulator. Leakage in the fuel hoses or pipes. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5115 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5116 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5117 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5118 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5119 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5120 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5121 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5122 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5123 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5124 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5125 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5126 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5127 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5128 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5129 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5130 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5131 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5132 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5133 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5134 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5135 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5136 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5137 Fuel Pump Relay: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5138 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5139 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5140 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5141 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5142 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5143 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5144 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5145 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5146 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5147 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5148 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5149 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5150 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5151 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5152 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5153 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5154 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5155 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5156 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5157 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5158 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5159 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5160 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5161 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5162 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5163 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5164 Fuel Pump Relay: Connector Views For Connector Views refer to "Powertrain Management : Diagrams". Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Page 5165 Fuel Pump Relay: Description and Operation PURPOSE/OPERATION The Programed Fuel Injection (PGM-FI) Main Relay actually contains two individual Relays. This Relay is located at the left side of the Cowl. One Relay is energized whenever the Ignition is "ON" which supplies the Battery voltage to the Engine Control Module (ECM), power to the Fuel Injectors, and power for the second Relay. The second Relay is energized for two seconds when the Ignition is switched "ON", and when the Engine is running, to supply power to the Fuel Pump. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Page 5166 Fuel Pump Relay: Testing and Inspection NOTE: If the car starts and continues to run, the PGM-FI main relay is OK. 1. Remove the PGM-FI main relay. 2. Attach the battery positive terminal to the No. 6 terminal and the battery negative terminal to the No. 8 terminal of the PGM-FI main relay. Then check for continuity between the No. 5 terminal and No. 7 terminal of the PGM-FI main relay. - If there is continuity, go on to step 3. - If there is no continuity, replace the relay and retest. 3. Attach the battery positive terminal to the No. 5 terminal and the battery negative terminal to the No. 2 terminal of the PGM-FI main relay. Then check that there is continuity between the No. 1 terminal and No. 3 terminal of the PGM-FI main relay. - If there is continuity, go on to step 4. - If there is no continuity, replace the relay and retest. 4. Attach the battery positive terminal to the No. 3 terminal and the battery negative terminal to the No. 8 terminal of the PGM-FI main relay. Then check that there is continuity between the No. 5 terminal and No. 7 terminal of the PGM-FI main relay. - If there is continuity, the relay is OK. - If there is no continuity, replace the relay and retest. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Page 5167 FLOWCHART PART 1 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Page 5168 FLOWCHART PART 2 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Diagrams > Diagram Information and Instructions Fuel Supply Line: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Diagrams > Diagram Information and Instructions > Page 5176 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Diagrams > Diagram Information and Instructions > Page 5177 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Diagrams > Diagram Information and Instructions > Page 5178 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Diagrams > Diagram Information and Instructions > Page 5179 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Diagrams > Diagram Information and Instructions > Page 5180 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Diagrams > Diagram Information and Instructions > Page 5181 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Diagrams > Diagram Information and Instructions > Page 5182 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Diagrams > Diagram Information and Instructions > Page 5183 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Diagrams > Diagram Information and Instructions > Page 5184 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Diagrams > Diagram Information and Instructions > Page 5185 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Diagrams > Diagram Information and Instructions > Page 5186 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Diagrams > Diagram Information and Instructions > Page 5187 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Diagrams > Diagram Information and Instructions > Page 5188 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Diagrams > Diagram Information and Instructions > Page 5189 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Diagrams > Diagram Information and Instructions > Page 5190 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Diagrams > Diagram Information and Instructions > Page 5191 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Diagrams > Diagram Information and Instructions > Page 5192 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Diagrams > Diagram Information and Instructions > Page 5193 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Diagrams > Diagram Information and Instructions > Page 5194 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Diagrams > Diagram Information and Instructions > Page 5195 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Diagrams > Diagram Information and Instructions > Page 5196 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Diagrams > Diagram Information and Instructions > Page 5197 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Diagrams > Diagram Information and Instructions > Page 5198 Fuel Supply Line: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Diagrams > Diagram Information and Instructions > Page 5199 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Diagrams > Diagram Information and Instructions > Page 5200 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Diagrams > Diagram Information and Instructions > Page 5201 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Diagrams > Diagram Information and Instructions > Page 5202 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Diagrams > Diagram Information and Instructions > Page 5203 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Diagrams > Diagram Information and Instructions > Page 5204 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Diagrams > Diagram Information and Instructions > Page 5205 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Diagrams > Diagram Information and Instructions > Page 5206 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Diagrams > Diagram Information and Instructions > Page 5207 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Diagrams > Diagram Information and Instructions > Page 5208 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Diagrams > Diagram Information and Instructions > Page 5209 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Diagrams > Diagram Information and Instructions > Page 5210 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Diagrams > Diagram Information and Instructions > Page 5211 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Diagrams > Diagram Information and Instructions > Page 5212 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Diagrams > Diagram Information and Instructions > Page 5213 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Diagrams > Diagram Information and Instructions > Page 5214 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Diagrams > Diagram Information and Instructions > Page 5215 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Diagrams > Diagram Information and Instructions > Page 5216 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Diagrams > Diagram Information and Instructions > Page 5217 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Diagrams > Diagram Information and Instructions > Page 5218 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Diagrams > Diagram Information and Instructions > Page 5219 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Diagrams > Diagram Information and Instructions > Page 5220 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Diagrams > Diagram Information and Instructions > Page 5221 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Diagrams > Diagram Information and Instructions > Page 5222 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Diagrams > Diagram Information and Instructions > Page 5223 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Diagrams > Diagram Information and Instructions > Page 5224 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Diagrams > Page 5225 Fuel Supply Line: Testing and Inspection Check all fuel system lines and hoses for damage, leaks or deterioration and replace if necessary. Check all hose clamps and retighten if necessary. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Component Information > Specifications Fuel Tank: Specifications Capacity ............................................................................................................................................... ....................................... 45 liters (11.9 US Gallons) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Component Information > Specifications > Page 5229 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Component Information > Specifications > Page 5230 Fuel Tank: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 degrees C (1000 degrees F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Component Information > Specifications > Page 5231 Fuel Tank: Service and Repair REPLACEMENT WARNING: Do not smoke while working on fuel system. Keep open frame away from your work area. 1. Relieve the fuel pressure. 2. Jack up the car and support with jackstands. 3. Remove the drain bolt and drain the fuel into an approved container. 4. Remove the exhaust pipe heat shield. 5. Remove the rear seat and the access panel. 6. Disconnect the connectors from the fuel gauge sending unit and the fuel pump, then remove the fuel feed pipe and return hose. CAUTION: Be sure to turn the ignition switch OFF before disconnecting the wires. 7. Remove the fuel hose protectors. 8. Disconnect the hoses. CAUTION: When disconnecting the hoses, slide back the clamps, then twist hoses as you pull to avoid damaging them 9. Place a jack, or other support, under the tank. 10. Remove the strap bolts and nuts, and let the straps fall free. 11. Remove the fuel tank. NOTE: The tank may stick on the undercoat applied to its mount. To remove, carefully pry it off the mount. 12. Install a new washer on the drain bolt and the fuel pump line, then install parts in the reverse order of removal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Locations Fuel Tank Unit: Locations Below Center Of Rear Seat Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control (Linkage) > Component Information > Diagrams > Diagram Information and Instructions Idle Speed Control (Linkage): Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control (Linkage) > Component Information > Diagrams > Diagram Information and Instructions > Page 5239 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control (Linkage) > Component Information > Diagrams > Diagram Information and Instructions > Page 5240 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control (Linkage) > Component Information > Diagrams > Diagram Information and Instructions > Page 5241 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control (Linkage) > Component Information > Diagrams > Diagram Information and Instructions > Page 5242 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control (Linkage) > Component Information > Diagrams > Diagram Information and Instructions > Page 5243 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control (Linkage) > Component Information > Diagrams > Diagram Information and Instructions > Page 5244 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control (Linkage) > Component Information > Diagrams > Diagram Information and Instructions > Page 5245 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control (Linkage) > Component Information > Diagrams > Diagram Information and Instructions > Page 5246 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control (Linkage) > Component Information > Diagrams > Diagram Information and Instructions > Page 5247 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control (Linkage) > Component Information > Diagrams > Diagram Information and Instructions > Page 5248 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control (Linkage) > Component Information > Diagrams > Diagram Information and Instructions > Page 5249 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control (Linkage) > Component Information > Diagrams > Diagram Information and Instructions > Page 5250 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control (Linkage) > Component Information > Diagrams > Diagram Information and Instructions > Page 5251 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control (Linkage) > Component Information > Diagrams > Diagram Information and Instructions > Page 5252 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control (Linkage) > Component Information > Diagrams > Diagram Information and Instructions > Page 5253 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control (Linkage) > Component Information > Diagrams > Diagram Information and Instructions > Page 5254 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control (Linkage) > Component Information > Diagrams > Diagram Information and Instructions > Page 5255 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control (Linkage) > Component Information > Diagrams > Diagram Information and Instructions > Page 5256 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control (Linkage) > Component Information > Diagrams > Diagram Information and Instructions > Page 5257 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control (Linkage) > Component Information > Diagrams > Diagram Information and Instructions > Page 5258 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control (Linkage) > Component Information > Diagrams > Diagram Information and Instructions > Page 5259 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control (Linkage) > Component Information > Diagrams > Diagram Information and Instructions > Page 5260 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control (Linkage) > Component Information > Diagrams > Diagram Information and Instructions > Page 5261 Idle Speed Control (Linkage): Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control (Linkage) > Component Information > Diagrams > Diagram Information and Instructions > Page 5262 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control (Linkage) > Component Information > Diagrams > Diagram Information and Instructions > Page 5263 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control (Linkage) > Component Information > Diagrams > Diagram Information and Instructions > Page 5264 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control (Linkage) > Component Information > Diagrams > Diagram Information and Instructions > Page 5265 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control (Linkage) > Component Information > Diagrams > Diagram Information and Instructions > Page 5266 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control (Linkage) > Component Information > Diagrams > Diagram Information and Instructions > Page 5267 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control (Linkage) > Component Information > Diagrams > Diagram Information and Instructions > Page 5268 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control (Linkage) > Component Information > Diagrams > Diagram Information and Instructions > Page 5269 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control (Linkage) > Component Information > Diagrams > Diagram Information and Instructions > Page 5270 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control (Linkage) > Component Information > Diagrams > Diagram Information and Instructions > Page 5271 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control (Linkage) > Component Information > Diagrams > Diagram Information and Instructions > Page 5272 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control (Linkage) > Component Information > Diagrams > Diagram Information and Instructions > Page 5273 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control (Linkage) > Component Information > Diagrams > Diagram Information and Instructions > Page 5274 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control (Linkage) > Component Information > Diagrams > Diagram Information and Instructions > Page 5275 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control (Linkage) > Component Information > Diagrams > Diagram Information and Instructions > Page 5276 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control (Linkage) > Component Information > Diagrams > Diagram Information and Instructions > Page 5277 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control (Linkage) > Component Information > Diagrams > Diagram Information and Instructions > Page 5278 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control (Linkage) > Component Information > Diagrams > Diagram Information and Instructions > Page 5279 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control (Linkage) > Component Information > Diagrams > Diagram Information and Instructions > Page 5280 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control (Linkage) > Component Information > Diagrams > Diagram Information and Instructions > Page 5281 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control (Linkage) > Component Information > Diagrams > Diagram Information and Instructions > Page 5282 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control (Linkage) > Component Information > Diagrams > Diagram Information and Instructions > Page 5283 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control (Linkage) > Component Information > Diagrams > Diagram Information and Instructions > Page 5284 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control (Linkage) > Component Information > Diagrams > Diagram Information and Instructions > Page 5285 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control (Linkage) > Component Information > Diagrams > Diagram Information and Instructions > Page 5286 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control (Linkage) > Component Information > Diagrams > Diagram Information and Instructions > Page 5287 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Locations Idle Speed/Throttle Actuator - Electronic: Locations Center Rear Of Engine Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions Idle Speed/Throttle Actuator - Electronic: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5293 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5294 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5295 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5296 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5297 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5298 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5299 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5300 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5301 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5302 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5303 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5304 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5305 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5306 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5307 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5308 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5309 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5310 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5311 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5312 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5313 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5314 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5315 Idle Speed/Throttle Actuator - Electronic: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5316 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5317 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5318 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5319 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5320 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5321 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5322 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5323 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5324 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5325 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5326 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5327 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5328 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5329 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5330 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5331 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5332 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5333 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5334 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5335 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5336 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5337 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5338 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5339 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5340 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 5341 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 5342 Idle Speed/Throttle Actuator - Electronic: Description and Operation PURPOSE The IAC Valve changes the amount of air bypassing the Throttle Body in response to a current signal from the Engine Control Module (ECM) in order to maintain the proper idle speed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 5343 Idle Speed/Throttle Actuator - Electronic: Testing and Inspection Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 5344 The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 14: A problem in the Idle Air Control (IAC) Valve circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations PGM-FI Main Relay: Locations The PGM-FI relay is located under the left side of the dash. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions PGM-FI Main Relay: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5350 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5351 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5352 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5353 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5354 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5355 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5356 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5357 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5358 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5359 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5360 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5361 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5362 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5363 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5364 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5365 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5366 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5367 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5368 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5369 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5370 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5371 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5372 PGM-FI Main Relay: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5373 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5374 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5375 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5376 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5377 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5378 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5379 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5380 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5381 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5382 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5383 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5384 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5385 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5386 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5387 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5388 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5389 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5390 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5391 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5392 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5393 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5394 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5395 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5396 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5397 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5398 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 5399 PGM-FI Main Relay: Description and Operation PURPOSE/OPERATION The PGM-FI main relay actually contains two individual relays. The relay is located at the left side of the cowl. One relay is energized whenever the ignition is on, which supplies the battery voltage to the ECM, power to the fuel injectors, and power for the second relay. The second relay is energized for 2 seconds when the ignition is switched on, and when the engine is running, to supply power to the fuel pump. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 5400 PGM-FI Main Relay: Testing and Inspection NOTE: If the car starts and continues to run, the PGM-FI main relay is OK. 1. Remove the PGM-FI main relay. 2. Attach the battery positive terminal to the No. 6 terminal and the battery negative terminal to the No. 8 terminal of the PGM-FI main relay. Then check for continuity between the No. 5 terminal and No. 7 terminal of the PGM-FI main relay. ^ If there is continuity, go on to step 3. ^ If there is no continuity, replace the relay and retest. 3. Attach the battery positive terminal to the No. 5 terminal and the battery negative terminal to the No. 2 terminal of the PGM-FI main relay. Then check that there is continuity between the No. 1 terminal and No. 3 terminal of the PGM-FI main relay. ^ If there is continuity, go on to step 4. ^ If there is no continuity, replace the relay and retest. 4. Attach the battery positive terminal to the No. 3 terminal and the battery negative terminal to the No. 8 terminal of the PGM-FI main relay. Then check that there is continuity between the No. 5 terminal and No. 7 terminal of the PGM-FI main relay. ^ If there is continuity, the relay is OK. ^ If there is no continuity, replace the relay and retest. Main Relay And Harness Inspection Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 5401 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 5402 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5409 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5410 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5411 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5412 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5413 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5414 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5415 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5416 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5417 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5418 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5419 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5420 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5421 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5422 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5423 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5424 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5425 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5426 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5427 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5428 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5429 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5430 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5431 Fuel Pump Relay: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5432 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5433 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5434 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5435 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5436 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5437 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5438 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5439 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5440 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5441 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5442 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5443 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5444 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5445 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5446 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5447 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5448 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5449 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5450 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5451 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5452 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5453 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5454 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5455 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5456 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5457 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5458 Fuel Pump Relay: Connector Views For Connector Views refer to "Powertrain Management : Diagrams". Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 5459 Fuel Pump Relay: Description and Operation PURPOSE/OPERATION The Programed Fuel Injection (PGM-FI) Main Relay actually contains two individual Relays. This Relay is located at the left side of the Cowl. One Relay is energized whenever the Ignition is "ON" which supplies the Battery voltage to the Engine Control Module (ECM), power to the Fuel Injectors, and power for the second Relay. The second Relay is energized for two seconds when the Ignition is switched "ON", and when the Engine is running, to supply power to the Fuel Pump. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 5460 Fuel Pump Relay: Testing and Inspection NOTE: If the car starts and continues to run, the PGM-FI main relay is OK. 1. Remove the PGM-FI main relay. 2. Attach the battery positive terminal to the No. 6 terminal and the battery negative terminal to the No. 8 terminal of the PGM-FI main relay. Then check for continuity between the No. 5 terminal and No. 7 terminal of the PGM-FI main relay. - If there is continuity, go on to step 3. - If there is no continuity, replace the relay and retest. 3. Attach the battery positive terminal to the No. 5 terminal and the battery negative terminal to the No. 2 terminal of the PGM-FI main relay. Then check that there is continuity between the No. 1 terminal and No. 3 terminal of the PGM-FI main relay. - If there is continuity, go on to step 4. - If there is no continuity, replace the relay and retest. 4. Attach the battery positive terminal to the No. 3 terminal and the battery negative terminal to the No. 8 terminal of the PGM-FI main relay. Then check that there is continuity between the No. 5 terminal and No. 7 terminal of the PGM-FI main relay. - If there is continuity, the relay is OK. - If there is no continuity, replace the relay and retest. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 5461 FLOWCHART PART 1 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 5462 FLOWCHART PART 2 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations PGM-FI Main Relay: Locations The PGM-FI relay is located under the left side of the dash. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions PGM-FI Main Relay: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5468 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5469 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5470 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5471 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5472 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5473 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5474 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5475 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5476 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5477 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5478 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5479 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5480 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5481 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5482 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5483 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5484 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5485 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5486 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5487 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5488 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5489 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5490 PGM-FI Main Relay: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5491 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5492 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5493 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5494 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5495 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5496 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5497 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5498 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5499 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5500 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5501 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5502 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5503 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5504 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5505 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5506 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5507 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5508 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5509 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5510 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5511 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5512 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5513 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5514 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5515 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 5516 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 5517 PGM-FI Main Relay: Description and Operation PURPOSE/OPERATION The PGM-FI main relay actually contains two individual relays. The relay is located at the left side of the cowl. One relay is energized whenever the ignition is on, which supplies the battery voltage to the ECM, power to the fuel injectors, and power for the second relay. The second relay is energized for 2 seconds when the ignition is switched on, and when the engine is running, to supply power to the fuel pump. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 5518 PGM-FI Main Relay: Testing and Inspection NOTE: If the car starts and continues to run, the PGM-FI main relay is OK. 1. Remove the PGM-FI main relay. 2. Attach the battery positive terminal to the No. 6 terminal and the battery negative terminal to the No. 8 terminal of the PGM-FI main relay. Then check for continuity between the No. 5 terminal and No. 7 terminal of the PGM-FI main relay. ^ If there is continuity, go on to step 3. ^ If there is no continuity, replace the relay and retest. 3. Attach the battery positive terminal to the No. 5 terminal and the battery negative terminal to the No. 2 terminal of the PGM-FI main relay. Then check that there is continuity between the No. 1 terminal and No. 3 terminal of the PGM-FI main relay. ^ If there is continuity, go on to step 4. ^ If there is no continuity, replace the relay and retest. 4. Attach the battery positive terminal to the No. 3 terminal and the battery negative terminal to the No. 8 terminal of the PGM-FI main relay. Then check that there is continuity between the No. 5 terminal and No. 7 terminal of the PGM-FI main relay. ^ If there is continuity, the relay is OK. ^ If there is no continuity, replace the relay and retest. Main Relay And Harness Inspection Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 5519 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PGM-FI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 5520 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Resonator (IAR) <--> [Resonator, Intake Air] > Component Information > Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Resonator (IAR) <--> [Resonator, Intake Air] > Component Information > Locations > Page 5524 Intake Air Resonator (IAR): Description and Operation The intake air resonator provides additional silencing as air is drawn into the intake air system. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5530 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5531 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5532 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5533 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5534 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5535 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5536 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5537 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5538 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5539 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5540 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5541 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5542 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5543 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5544 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5545 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5546 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5547 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5548 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5549 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5550 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5551 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5552 Air Flow Meter/Sensor: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5553 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5554 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5555 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5556 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5557 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5558 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5559 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5560 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5561 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5562 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5563 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5564 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5565 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5566 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5567 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5568 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5569 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5570 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5571 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5572 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5573 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5574 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5575 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5576 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5577 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5578 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions Throttle Full Open Switch: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5583 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5584 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5585 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5586 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5587 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5588 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5589 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5590 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5591 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5592 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5593 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5594 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5595 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5596 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5597 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5598 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5599 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5600 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5601 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5602 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5603 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5604 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5605 Throttle Full Open Switch: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5606 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5607 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5608 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5609 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5610 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5611 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5612 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5613 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5614 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5615 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5616 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5617 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5618 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5619 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5620 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5621 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5622 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5623 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5624 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5625 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5626 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5627 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5628 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5629 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5630 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5631 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations Center Rear Of Engine Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 5635 Throttle Position Sensor: Diagrams For Connector Views refer to "Powertrain Management : Diagrams". Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 5636 Throttle Position Sensor: Description and Operation PURPOSE/OPERATION The TP Sensor is a Potentiometer. It is connected to the Throttle Valve Shaft. As the Throttle Position changes, the Throttle Position Sensor varies the voltage signal to the Engine Control Module (ECM). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations > Page 5640 Throttle Body: Description and Operation PURPOSE/OPERATION The throttle body is of the single-barrel side-draft type. The lower portion of the throttle valve is heated by engine coolant which is fed from the cylinder head. The idle adjusting screw which increases/decreases bypass air and the evaporative emission (EVAP) control canister port are located on the top of the throttle body. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations > Page 5641 Throttle Body: Testing and Inspection CAUTION: Do not adjust the throttle stop screw. It is preset at the factory. 1. Start the engine and allow it to reach normal operating temperature (the radiator fan comes on). 2. Disconnect the vacuum hose (to the EVAP control canister) from the top of the throttle body; connect a vacuum gauge to the throttle body. 3. Allow the engine to idle and check that the gauge indicates no vacuum. ^ If there is vacuum, check the throttle cable. 4. Check that vacuum is indicated on the gauge when the throttle is opened slightly from idle. ^ If the gauge indicates no vacuum, check the throttle body port. If the throttle body port is clogged, clean it with carburetor cleaner. 5. Stop the engine and check that the throttle cable operates smoothly without binding or sticking. ^ If there are any abnormalities in the above steps, check for: - Excessive wear or play in the throttle valve shaft. - Sticky or binding throttle lever at full close position. - Clearance between throttle stop screw and throttle lever at full close position. Replace the throttle body if there is excessive play in the throttle valve shaft or if the shaft is binding or sticking. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations > Page 5642 Throttle Body: Service and Repair D16Z6, D15B7 ENGINE D15B8, D15Z1 ENGINE CAUTION: ^ The throttle stop screw is non-adjustable. ^ After reassembly, adjust the throttle cable, and A/T throttle control cable for cars with A/T. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Specifications Throttle Cable/Linkage: Specifications Accelerator cable free play ........................................................................................................................................................ 10 - 12 mm (0.39 - 0.47 in.) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Specifications > Page 5646 Throttle Cable/Linkage: Testing and Inspection 1. Warm up the engine to normal operating temperature (the radiator fan comes on). 2. Check that the throttle cable operates smoothly with no binding or sticking. Repair as necessary. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Specifications > Page 5647 Throttle Cable/Linkage: Adjustments 3. Check cable free play at the throttle linkage. Cable deflection: 10-12 mm (0.39-0.47 in.). 4. If deflection is not within specs, loosen the locknut, turn the adjusting nut until the deflection is as specified, then retighten the locknut. 5. With the cable properly adjusted, check the throttle valve to be sure it opens fully when you push the accelerator pedal to the floor. Also check the throttle valve to be sure it returns to the idle position whenever you release the accelerator. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Specifications > Page 5648 Throttle Cable/Linkage: Service and Repair 1. Fully open the throttle valve, then install the throttle cable in the throttle linkage and install the cable housing in the cable bracket. 2. Warm up the engine to normal operating temperature (the radiator fan comes on). 3. Hold the cable sheath, removing all slack from the cable. 4. Turn the adjusting nut until it is 3 mm (0.12 in) away from the cable bracket. 5. Tighten the locknut. The cable deflection should now be 10-12 mm (0.39-0.47 in.). If not, see Inspection/Adjustment. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions Throttle Full Open Switch: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5653 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5654 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5655 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5656 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5657 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5658 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5659 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5660 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5661 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5662 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5663 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5664 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5665 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5666 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5667 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5668 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5669 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5670 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5671 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5672 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5673 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5674 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5675 Throttle Full Open Switch: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5676 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5677 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5678 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5679 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5680 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5681 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5682 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5683 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5684 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5685 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5686 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5687 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5688 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5689 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5690 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5691 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5692 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5693 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5694 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5695 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5696 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5697 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5698 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5699 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5700 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Full Open Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5701 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations Center Rear Of Engine Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 5705 Throttle Position Sensor: Diagrams For Connector Views refer to "Powertrain Management : Diagrams". Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 5706 Throttle Position Sensor: Description and Operation PURPOSE/OPERATION The TP Sensor is a Potentiometer. It is connected to the Throttle Valve Shaft. As the Throttle Position changes, the Throttle Position Sensor varies the voltage signal to the Engine Control Module (ECM). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications Firing Order: Specifications Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > System Check Connector <--> [Ignition Timing Connector] > Component Information > Locations > Component Locations System Check Connector: Component Locations The Service Check Connector is located behind the glove box. CAUTION: Do not use a jumper wire on the Data Link Connector. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > System Check Connector <--> [Ignition Timing Connector] > Component Information > Locations > Component Locations > Page 5716 System Check Connector: Connector Locations The Service Check Connector is located behind the glove box. CAUTION: Do not use a jumper wire on the Data Link Connector. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Timing Marks and Indicators > System Information > Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Description and Operation Camshaft Position Sensor: Description and Operation PURPOSE/OPERATION The CKP Sensor determines timing for Fuel Injection and ignition of each Cylinder and also detects Engine speed. The TDC Sensor determines Ignition Timing at start-up (cranking) and when crank angle is abnormal. The CYP Sensor detects the position of No. 1 Cylinder for sequential fuel injection to each Cylinder. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Page 5726 Camshaft Position Sensor: Testing and Inspection Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Page 5727 The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 4: A problem in the Crankshaft Position (CKP) Sensor circuit. The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 8: A problem in the Top Dead Center (TDC) Sensor circuit. The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 9: A problem in the Cylinder Position (CYP) Sensor circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5732 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5733 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5734 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5735 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5736 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5737 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5738 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5739 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5740 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5741 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5742 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5743 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5744 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5745 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5746 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5747 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5748 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5749 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5750 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5751 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5752 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5753 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5754 Crankshaft Position Sensor: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5755 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5756 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5757 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5758 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5759 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5760 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5761 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5762 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5763 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5764 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5765 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5766 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5767 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5768 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5769 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5770 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5771 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5772 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5773 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5774 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5775 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5776 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5777 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5778 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5779 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5780 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 5781 Crankshaft Position Sensor: Testing and Inspection Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 5782 The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 4: A problem in the Crankshaft Position (CKP) Sensor circuit. The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 8: A problem in the Top Dead Center (TDC) Sensor circuit. The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 9: A problem in the Cylinder Position (CYP) Sensor circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Distributor Cap > Component Information > Testing and Inspection Distributor Cap: Testing and Inspection Check the following points, repair or replace as needed if a problem is found. 1. There must be no cracking in the cap. 2. There must be no damage to the cap's electrodes. 3. Clean away any accumulated dirt from the cap. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Ignition Rotor > Component Information > Testing and Inspection Ignition Rotor: Testing and Inspection Check the following points, repair or replace as needed if a problem is found. 1. There must be no cracking in the rotor. 2. There must be no damage to the rotor's electrode. 3. Clean away any accumulated dirt from the rotor. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications Resistance at 20°C (68°F) ................................................................................................................... ......................................................... 25 K Ohms max Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions Ignition Cable: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 5795 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 5796 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 5797 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 5798 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 5799 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 5800 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 5801 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 5802 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 5803 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 5804 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 5805 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 5806 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 5807 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 5808 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 5809 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 5810 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 5811 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 5812 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 5813 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 5814 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 5815 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 5816 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 5817 Ignition Cable: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 5818 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 5819 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 5820 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 5821 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 5822 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 5823 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 5824 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 5825 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 5826 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 5827 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 5828 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 5829 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 5830 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 5831 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 5832 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 5833 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 5834 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 5835 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 5836 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 5837 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 5838 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 5839 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 5840 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 5841 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 5842 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 5843 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Diagrams > Page 5844 Ignition Cable: Testing and Inspection CAUTION: Carefully remove the ignition wires by pulling on the rubber boots. Do not bend the wires; you might break them inside. 1. Check the condition of the wire terminals. If any terminal is corroded, clean it, and if it is broken or distorted, replace the wire. 2. Connect ohmmeter probes and measure resistance. Resistance: 25 k Ohms max. at 70° F (20°C) 3. If resistance exceeds 25 k Ohms, replace the ignition wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications Ignition Coil: Specifications Rated Voltage ...................................................................................................................................... .................................................................... 12 Volts Resistance at 20°C (68°F): Primary Winding .................................................................................................................................. ............................................... 0.6 - 0.8 Ohms Secondary Winding ..................................................... .................................................................................................................. 12.8 - 19.2 kOhms Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 5848 Ignition Coil: Locations The ignition coil is located inside the distributor. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions Ignition Coil: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5851 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5852 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5853 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5854 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5855 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5856 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5857 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5858 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5859 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5860 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5861 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5862 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5863 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5864 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5865 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5866 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5867 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5868 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5869 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5870 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5871 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5872 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5873 Ignition Coil: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5874 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5875 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5876 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5877 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5878 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5879 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5880 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5881 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5882 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5883 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5884 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5885 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5886 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5887 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5888 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5889 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5890 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5891 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5892 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5893 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5894 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5895 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5896 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5897 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5898 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 5899 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 5900 Ignition Coil: Description and Operation Ignition Coil Schematic Diagram PURPOSE The Ignition Coil transforms battery voltage into ignition voltage and delivers it in the form of a high voltage surge to the secondary ignition components. OPERATION The ignition coil (located in the distributor) uses the principle of mutual induction to step up battery (low) voltage to ignition (high) voltage. The ignition coil contains two sets of copper wire windings around a soft iron core. The primary winding is made of a hundred or so turns of a heavy gage wire. It is connected to the battery through the ignition switch (+) and to the ignition control module (ignitor) (-) so that current flows through it, thus creating a magnetic field. The secondary winding is connected to the coil output tower through the iron core. It contains several thousand turns of wire wound directly onto the iron core. The ratio of the number of wraps in the secondary winding to the number of wraps in the primary windings determines the output voltage of the coil. The ratio is approx. 1 to 110. When current flow in the primary winding is stopped (by the ignitor breaking the circuit ground), the collapse of the magnetic field causes a high voltage (20,000 volts or more) to be induced in the secondary windings. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 5901 Ignition Coil: Testing and Inspection 1. With the ignition switch OFF, remove the distributor ignition cap. 2. Remove the two screws to disconnect the BLK/YEL and WHT/BLU wires from the terminals A (+) and B (-) respectively. 3. Using an ohmmeter, measure resistance between the terminals. Replace the coil if the resistance is not within specifications. NOTE: Resistance will vary with the coil temperature; specifications are at 68°F (2O° C) Primary Winding Resistance (Between the A and B terminals): 0.6 - 0.8 Ohms Secondary Winding Resistance (Between the A and secondary winding terminals): 12.8 - 19.2 kOhms Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 5902 Ignition Coil: Service and Repair 1. With ignition switch OFF, remove the distributor ignition cap, rotor and cap seal, then remove the leak cover. 2. Remove the two screws to disconnect the BLK/YEL and WHT/BLU wires from the terminals. 3. Remove the two screws and slide the ignition coil out of the distributor ignition housing. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions Ignition Control Module: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5908 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5909 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5910 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5911 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5912 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5913 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5914 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5915 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5916 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5917 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5918 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5919 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5920 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5921 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5922 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5923 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5924 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5925 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5926 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5927 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5928 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5929 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5930 Ignition Control Module: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5931 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5932 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5933 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5934 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5935 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5936 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5937 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5938 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5939 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5940 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5941 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5942 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5943 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5944 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5945 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5946 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5947 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5948 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5949 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5950 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5951 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5952 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5953 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5954 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5955 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5956 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5957 Ignition Control Module: Connector Views For Connector Views refer to "Powertrain Management : Diagrams". Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Page 5958 Ignition Control Module: Testing and Inspection NOTE: Perform an input test for the ignition control module (ICM) after finishing the fundamental tests for the ignition system and the fuel and emissions systems. The tachometer should operate normally. 1. Remove the distributor ignition cap, the distributor ignition rotor, and the leak cover. 2. Disconnect the BLK/YEL, WHT/BLU, YEL/GRN, and BLU wires from the ICM. 3. Turn the ignition switch ON. Check for voltage between the BLK/YEL wire and body ground. There should be battery voltage. ^ If there is no battery voltage, check the BLK/YEL wire between the ignition switch and the ICM. ^ If there is battery voltage, go to step 4. 4. Turn the ignition switch ON. Check for voltage between the WHT/BLU wire and body ground. There should be battery voltage. ^ If there is no battery voltage, check: Ignition coil. - WHT/BLU wire between the ignition coil and the ICM. ^ If there is battery voltage, go to step 5. 5. Check the YEL/GRN wire between the ECM and the ICM. 6. Check the BLU wire between the tachometer and the ICM. 7. If all tests are normal, replace the ICM. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Service and Repair > Removal Ignition Control Module: Service and Repair Removal 1. Disconnect the 2-P and 8-P connectors from the distributor. 2. Disconnect the ignition wires from the distributor ignition cap. 3. Remove the distributor mounting bolts, then remove the distributor from the cylinder bead. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Service and Repair > Removal > Page 5961 Ignition Control Module: Service and Repair Installation 1. Coat a new 0-ring with engine oil, then install it. 2. Slip the distributor into position. NOTE: The lugs on the end of the distributor and its mating grooves in the camshaft end are both offset to eliminate the possibility of installing the distributor 180° out of time. 3. Install the mounting bolts and tighten them temporarily. 4. Connect the 2-P and 8-P connectors to the distributor. 5. Connect the ignition wires as shown. 6. Set the timing with a timing light. 7. After setting the timing, tighten the mounting bolts. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Service and Repair > Removal > Page 5962 Ignition Control Module: Service and Repair Overhaul Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Service and Repair > Removal > Page 5963 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Service and Repair > Removal > Page 5964 Ignition Control Module: Service and Repair Reassembly Reassemble the distributor in the reverse order of disassembly. 1. Install the distributor ignition rotor, then turn it so that it faces in the direction shown (Toward the No. 1 cylinder). 2. Slip the thrust washer and coupling onto the shaft. 3. Check that the distributor ignition rotor is still pointing toward the No. 1 cylinder, then align the index mark on the distributor ignition housing with the index mark on the coupling. 4. Drive in the pin and secure it with the pin retainer. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > System Check Connector <--> [Ignition Timing Connector] > Component Information > Locations > Component Locations System Check Connector: Component Locations The Service Check Connector is located behind the glove box. CAUTION: Do not use a jumper wire on the Data Link Connector. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > System Check Connector <--> [Ignition Timing Connector] > Component Information > Locations > Component Locations > Page 5969 System Check Connector: Connector Locations The Service Check Connector is located behind the glove box. CAUTION: Do not use a jumper wire on the Data Link Connector. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions Ignition Control Module: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5976 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5977 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5978 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5979 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5980 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5981 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5982 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5983 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5984 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5985 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5986 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5987 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5988 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5989 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5990 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5991 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5992 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5993 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5994 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5995 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5996 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5997 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5998 Ignition Control Module: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5999 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6000 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6001 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6002 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6003 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6004 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6005 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6006 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6007 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6008 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6009 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6010 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6011 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6012 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6013 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6014 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6015 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6016 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6017 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6018 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6019 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6020 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6021 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6022 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6023 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6024 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6025 Ignition Control Module: Connector Views For Connector Views refer to "Powertrain Management : Diagrams". Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Page 6026 Ignition Control Module: Testing and Inspection NOTE: Perform an input test for the ignition control module (ICM) after finishing the fundamental tests for the ignition system and the fuel and emissions systems. The tachometer should operate normally. 1. Remove the distributor ignition cap, the distributor ignition rotor, and the leak cover. 2. Disconnect the BLK/YEL, WHT/BLU, YEL/GRN, and BLU wires from the ICM. 3. Turn the ignition switch ON. Check for voltage between the BLK/YEL wire and body ground. There should be battery voltage. ^ If there is no battery voltage, check the BLK/YEL wire between the ignition switch and the ICM. ^ If there is battery voltage, go to step 4. 4. Turn the ignition switch ON. Check for voltage between the WHT/BLU wire and body ground. There should be battery voltage. ^ If there is no battery voltage, check: Ignition coil. - WHT/BLU wire between the ignition coil and the ICM. ^ If there is battery voltage, go to step 5. 5. Check the YEL/GRN wire between the ECM and the ICM. 6. Check the BLU wire between the tachometer and the ICM. 7. If all tests are normal, replace the ICM. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Service and Repair > Removal Ignition Control Module: Service and Repair Removal 1. Disconnect the 2-P and 8-P connectors from the distributor. 2. Disconnect the ignition wires from the distributor ignition cap. 3. Remove the distributor mounting bolts, then remove the distributor from the cylinder bead. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Service and Repair > Removal > Page 6029 Ignition Control Module: Service and Repair Installation 1. Coat a new 0-ring with engine oil, then install it. 2. Slip the distributor into position. NOTE: The lugs on the end of the distributor and its mating grooves in the camshaft end are both offset to eliminate the possibility of installing the distributor 180° out of time. 3. Install the mounting bolts and tighten them temporarily. 4. Connect the 2-P and 8-P connectors to the distributor. 5. Connect the ignition wires as shown. 6. Set the timing with a timing light. 7. After setting the timing, tighten the mounting bolts. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Service and Repair > Removal > Page 6030 Ignition Control Module: Service and Repair Overhaul Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Service and Repair > Removal > Page 6031 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Service and Repair > Removal > Page 6032 Ignition Control Module: Service and Repair Reassembly Reassemble the distributor in the reverse order of disassembly. 1. Install the distributor ignition rotor, then turn it so that it faces in the direction shown (Toward the No. 1 cylinder). 2. Slip the thrust washer and coupling onto the shaft. 3. Check that the distributor ignition rotor is still pointing toward the No. 1 cylinder, then align the index mark on the distributor ignition housing with the index mark on the coupling. 4. Drive in the pin and secure it with the pin retainer. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation Camshaft Position Sensor: Description and Operation PURPOSE/OPERATION The CKP Sensor determines timing for Fuel Injection and ignition of each Cylinder and also detects Engine speed. The TDC Sensor determines Ignition Timing at start-up (cranking) and when crank angle is abnormal. The CYP Sensor detects the position of No. 1 Cylinder for sequential fuel injection to each Cylinder. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Page 6037 Camshaft Position Sensor: Testing and Inspection Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Page 6038 The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 4: A problem in the Crankshaft Position (CKP) Sensor circuit. The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 8: A problem in the Top Dead Center (TDC) Sensor circuit. The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 9: A problem in the Cylinder Position (CYP) Sensor circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6043 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6044 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6045 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6046 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6047 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6048 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6049 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6050 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6051 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6052 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6053 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6054 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6055 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6056 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6057 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6058 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6059 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6060 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6061 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6062 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6063 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6064 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6065 Crankshaft Position Sensor: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6066 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6067 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6068 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6069 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6070 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6071 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6072 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6073 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6074 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6075 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6076 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6077 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6078 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6079 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6080 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6081 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6082 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6083 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6084 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6085 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6086 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6087 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6088 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6089 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6090 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6091 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 6092 Crankshaft Position Sensor: Testing and Inspection Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 6093 The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 4: A problem in the Crankshaft Position (CKP) Sensor circuit. The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 8: A problem in the Top Dead Center (TDC) Sensor circuit. The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 9: A problem in the Cylinder Position (CYP) Sensor circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System Unable To Key In Ignition Switch Ignition Switch Lock Cylinder: Technical Service Bulletins Starting System - Unable To Key In Ignition Switch Can't Turn Ignition Switch? Check for Locked Steering Got a service customer complaining he or she can't turn the ignition switch to start the engine? The reason could just be the steering column lock pin is engaged with the front wheels turned. Here's what typically happens: Some folks use the steering wheel to help support themselves while climbing in or out of the vehicle. This is very common among elderly or disabled drivers. Doing this turns the front wheels, which twists the tires against the ground. The twisted tires apply torque to the steering column. With the ignition switch in LOCK (0), the steering column lock pin is engaged. But the applied torque on the steering column binds the lock pin, making it tough to turn the ignition switch. The ignition switch won't turn to ON (II) if the lock pin isn't disengaged from the steering column. Tell your customer there's nothing wrong with the ignition switch itself. All he or she needs to do is turn the steering wheel from side to side while turning the switch. This usually releases the lock pin so the engine can be started. In some cases, though, your customer may need to give a good tug on the wheel. This could easily happen when parking on a hill and the wheels are turned sharply before the engine is shut off. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Gap and Torque Spark Plug: Specifications Gap and Torque Spark Plug Gap ................................................................................................................................... ........................................................ 1.1 mm (0.043 in) Spark Plug Torque ............................................................................................................................... ......................................................... 18 Nm (13 ft lb) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Gap and Torque > Page 6103 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 6104 Spark Plug: Testing and Inspection Spark Plug Inspection 1. Inspect the electrodes and ceramic insulator for: Burned or worn electrodes may be caused by: ^ Advanced ignition timing ^ Loose spark plug ^ Plug heat range too low ^ Insufficient cooling Fouled plug may be caused by: ^ Retarded ignition timing ^ Oil in combustion chamber ^ Incorrect spark plug gap ^ Plug heat range too high ^ Excessive idling/low speed running ^ Clogged air cleaner element ^ Deteriorated ignition coil or ignition wires 2. Adjust the gap with a suitable gapping tool. 3. Replace the plug if the center electrode is rounded as shown above. NOTE: Do not use spark plugs other than recommended types. These plugs are a new type (ISO standard). 4. Screw the plugs into the cylinder head finger tight, then torque them to 18 N-m (1.8 kg-m, 13 lb-ft). NOTE: Apply a small quantity of anti-seize compound to the plug threads before installing. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Ignition System > Tachometer Connector > Component Information > Locations Tachometer Connector: Locations Left Rear Corner Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations Shift Interlock Solenoid: Locations Below Center Console Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 6114 Shift Interlock Solenoid: Testing and Inspection 1. Remove instrument panel lower cover and knee bolster. 2. Remove steering column upper and lower covers. 3. Disconnect shift lock solenoid 2-P connector. Fig. 13 Shift Lock Solenoid Test Terminal 4. Connect battery power momentarily to No. 1 terminal of shift lock solenoid, Fig. 13, noting the following: a. Ensure power is not applied to terminal No. 2, as the solenoid will be shorted out. b. Ensure shift lock stop does not protrude when in On position. c. Ensure shift lock stop does protrude more than 0.30 inches when Off. 5. Check that shift lock releases when release lever is pushed. 6. Check that shift lock solenoid locks when lever is released. 7. If solenoid does not work as outlined, replace. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 6115 Shift Interlock Solenoid: Service and Repair 1. Remove instrument panel lower cover and knee bolster. 2. Remove steering column upper and lower covers. 3. Disconnect 2-P electrical connector from shift lock solenoid. 4. Remove shift lock extension. Fig. 16 Shift Lock Solenoid Replacement 5. Remove screw and detent spring washer, Fig. 16. 6. Remove shift lock solenoid. 7. Reverse procedure to install, noting the following: a. Ensure shift lock stop does not protrude when solenoid is On. b. Ensure shift lock solenoid does protrude more than 0.30 inches when shift lock is Off. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications Resistance ........................................................................................................................................... ............................... 14.1 - 15.5 Ohms at 25°C (77°F) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 6119 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 6120 Torque Converter Clutch Solenoid: Testing and Inspection NOTE: Lock-up control solenoid valves A and B must be removed/replaced as an assembly. 1. Disconnect the connector from the lock-up control solenoid valve A/B. 2. Measure the resistance between the No. 1 terminal (solenoid valve A) of the lock-up control solenoid valve connector and body ground, and between the No. 2 terminal (solenoid valve B) and body ground. Standard: 14.1 - 15.5 Ohms at 25°C (77°F) 3. Replace the lock-up control solenoid valve assembly if the resistance is out of specification. 4. Connect the No. 1 terminal of the lock-up control solenoid valve connector to the battery positive terminal and body ground. A clicking sound should be heard. Connect the No. 2 terminal to the battery positive terminal and body ground. A clicking sound should be heard. 5. If there is no clicking, check for continuity between the engine control module (ECM) A19 or A17 harness and body ground using the Test Harness: O7LAJ - PT3O1OA. NOTE: Always use the Test Harness (O7LAJ PT3O1OA) for checking. 6. Replace the lock-up control solenoid valve assembly if there is continuity between the ECM A19 or A17 harness and body ground. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 6121 Torque Converter Clutch Solenoid: Service and Repair 1. Remove the mounting bolts and lock-up control solenoid valve assembly. NOTE: Be sure to remove or replace the lock-up control solenoid valves A and B as an assembly. 2. Check the lock-up control solenoid valve oil passages for dust or dirt, and replace as an assembly, if necessary. 3. Clean the mounting surface and oil passages of the lock-up control solenoid valve assembly and install a new filter/gasket. 4. Check the connector for rust, dirt or oil and reconnect it securely. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Shift Interlock Control Module > Component Information > Locations Shift Interlock Control Module: Locations Behind Left Side Of Dash Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Locations Shift Interlock Switch: Locations Behind Left Side Of Dash Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > A/T Gear Position Signal <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Locations A/T Gear Position Signal: Locations Below Center Console Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > A/T Gear Position Signal <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Locations > Page 6135 A/T Gear Position Signal: Description and Operation PURPOSE This signals the Engine Control Module (ECM) when the Transmission is in Neutral or Park position. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > A/T Gear Position Signal <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Locations > Page 6136 A/T Gear Position Signal: Testing and Inspection Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > A/T Gear Position Signal <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Locations > Page 6137 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations Shift Interlock Solenoid: Locations Below Center Console Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 6144 Shift Interlock Solenoid: Testing and Inspection 1. Remove instrument panel lower cover and knee bolster. 2. Remove steering column upper and lower covers. 3. Disconnect shift lock solenoid 2-P connector. Fig. 13 Shift Lock Solenoid Test Terminal 4. Connect battery power momentarily to No. 1 terminal of shift lock solenoid, Fig. 13, noting the following: a. Ensure power is not applied to terminal No. 2, as the solenoid will be shorted out. b. Ensure shift lock stop does not protrude when in On position. c. Ensure shift lock stop does protrude more than 0.30 inches when Off. 5. Check that shift lock releases when release lever is pushed. 6. Check that shift lock solenoid locks when lever is released. 7. If solenoid does not work as outlined, replace. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 6145 Shift Interlock Solenoid: Service and Repair 1. Remove instrument panel lower cover and knee bolster. 2. Remove steering column upper and lower covers. 3. Disconnect 2-P electrical connector from shift lock solenoid. 4. Remove shift lock extension. Fig. 16 Shift Lock Solenoid Replacement 5. Remove screw and detent spring washer, Fig. 16. 6. Remove shift lock solenoid. 7. Reverse procedure to install, noting the following: a. Ensure shift lock stop does not protrude when solenoid is On. b. Ensure shift lock solenoid does protrude more than 0.30 inches when shift lock is Off. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications Resistance ........................................................................................................................................... ............................... 14.1 - 15.5 Ohms at 25°C (77°F) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 6149 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 6150 Torque Converter Clutch Solenoid: Testing and Inspection NOTE: Lock-up control solenoid valves A and B must be removed/replaced as an assembly. 1. Disconnect the connector from the lock-up control solenoid valve A/B. 2. Measure the resistance between the No. 1 terminal (solenoid valve A) of the lock-up control solenoid valve connector and body ground, and between the No. 2 terminal (solenoid valve B) and body ground. Standard: 14.1 - 15.5 Ohms at 25°C (77°F) 3. Replace the lock-up control solenoid valve assembly if the resistance is out of specification. 4. Connect the No. 1 terminal of the lock-up control solenoid valve connector to the battery positive terminal and body ground. A clicking sound should be heard. Connect the No. 2 terminal to the battery positive terminal and body ground. A clicking sound should be heard. 5. If there is no clicking, check for continuity between the engine control module (ECM) A19 or A17 harness and body ground using the Test Harness: O7LAJ - PT3O1OA. NOTE: Always use the Test Harness (O7LAJ PT3O1OA) for checking. 6. Replace the lock-up control solenoid valve assembly if there is continuity between the ECM A19 or A17 harness and body ground. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 6151 Torque Converter Clutch Solenoid: Service and Repair 1. Remove the mounting bolts and lock-up control solenoid valve assembly. NOTE: Be sure to remove or replace the lock-up control solenoid valves A and B as an assembly. 2. Check the lock-up control solenoid valve oil passages for dust or dirt, and replace as an assembly, if necessary. 3. Clean the mounting surface and oil passages of the lock-up control solenoid valve assembly and install a new filter/gasket. 4. Check the connector for rust, dirt or oil and reconnect it securely. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Locations Shift Interlock Solenoid: Locations Below Center Console Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Locations > Page 6157 Shift Interlock Solenoid: Testing and Inspection 1. Remove instrument panel lower cover and knee bolster. 2. Remove steering column upper and lower covers. 3. Disconnect shift lock solenoid 2-P connector. Fig. 13 Shift Lock Solenoid Test Terminal 4. Connect battery power momentarily to No. 1 terminal of shift lock solenoid, Fig. 13, noting the following: a. Ensure power is not applied to terminal No. 2, as the solenoid will be shorted out. b. Ensure shift lock stop does not protrude when in On position. c. Ensure shift lock stop does protrude more than 0.30 inches when Off. 5. Check that shift lock releases when release lever is pushed. 6. Check that shift lock solenoid locks when lever is released. 7. If solenoid does not work as outlined, replace. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Locations > Page 6158 Shift Interlock Solenoid: Service and Repair 1. Remove instrument panel lower cover and knee bolster. 2. Remove steering column upper and lower covers. 3. Disconnect 2-P electrical connector from shift lock solenoid. 4. Remove shift lock extension. Fig. 16 Shift Lock Solenoid Replacement 5. Remove screw and detent spring washer, Fig. 16. 6. Remove shift lock solenoid. 7. Reverse procedure to install, noting the following: a. Ensure shift lock stop does not protrude when solenoid is On. b. Ensure shift lock solenoid does protrude more than 0.30 inches when shift lock is Off. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications Resistance ........................................................................................................................................... ............................... 14.1 - 15.5 Ohms at 25°C (77°F) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 6162 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 6163 Torque Converter Clutch Solenoid: Testing and Inspection NOTE: Lock-up control solenoid valves A and B must be removed/replaced as an assembly. 1. Disconnect the connector from the lock-up control solenoid valve A/B. 2. Measure the resistance between the No. 1 terminal (solenoid valve A) of the lock-up control solenoid valve connector and body ground, and between the No. 2 terminal (solenoid valve B) and body ground. Standard: 14.1 - 15.5 Ohms at 25°C (77°F) 3. Replace the lock-up control solenoid valve assembly if the resistance is out of specification. 4. Connect the No. 1 terminal of the lock-up control solenoid valve connector to the battery positive terminal and body ground. A clicking sound should be heard. Connect the No. 2 terminal to the battery positive terminal and body ground. A clicking sound should be heard. 5. If there is no clicking, check for continuity between the engine control module (ECM) A19 or A17 harness and body ground using the Test Harness: O7LAJ - PT3O1OA. NOTE: Always use the Test Harness (O7LAJ PT3O1OA) for checking. 6. Replace the lock-up control solenoid valve assembly if there is continuity between the ECM A19 or A17 harness and body ground. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 6164 Torque Converter Clutch Solenoid: Service and Repair 1. Remove the mounting bolts and lock-up control solenoid valve assembly. NOTE: Be sure to remove or replace the lock-up control solenoid valves A and B as an assembly. 2. Check the lock-up control solenoid valve oil passages for dust or dirt, and replace as an assembly, if necessary. 3. Clean the mounting surface and oil passages of the lock-up control solenoid valve assembly and install a new filter/gasket. 4. Check the connector for rust, dirt or oil and reconnect it securely. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications TYPE ................................................................................................................................................... ............................................................................. AF CAPACITY, Refill*: Accord 4cyl........................................................................................................................................... ........................................ 2.4 liters 2.5 quarts V6 ........................................................................................................................................................ ................................... 2.7 liters 2.9 quarts Civic, Del Sol ....................................................................................................................................... ........................................ 2.7 liters 2.9 quarts Prelude ................................................................................................................................................ .......................................... 2.4 liters 2.5 quarts Odyssey, Oasis ................................................................................................................................... ........................................... 2.4 liters 2.5 quarts *With the engine at operating temperature, shift transmission through all gears. Turn engine off and check fluid level within 1 minute. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 6169 Fluid - A/T: Fluid Type Specifications KEY TO LUBRICATION ABBREVIATIONS NOTE: Some manufacturer lubricant names may differ from the following list. If the manufacturer does not recommend a specific lubricant, use the following. AF Dexron(r)-III Automatic Transmission Fluid AP ATF-PLUS(r) Automatic Transmission Fluid BJ Suspension Lubricant BL Brake Lubricant CC Motor Oil, API Service CC CD Motor Oil, API Service CD CE Motor Oil, API Service CE CF-4 Motor Oil, API Service CF-4 DC Distributor Cam Lubricant EC Ethylene Glycol Coolant EP Extreme Pressure Gear Oil FA Automatic Transmission Fluid, Type F GC Wheel Bearing Grease, NLGI Classification GC GF-1 Motor Oil, API Service GF-1 (Starburst) GL-1 Gear Oil, API Service GL-1 GL-4 Gear Oil, API Service GL-4 GL-5 Gear Oil, API Service GL-5 GL-5* GL-5 Gear Oil for Limited Slip Differentials GLS Gear Lubricant, Special HB Hydraulic Brake Fluid, SAE J1703, DOT-3 or 4 HBH Hydraulic Brake Fluid, Extra Heavy Duty HG High Temperature Grease HP Hypoid Gear Oil HP* Hypoid Gear Oil for Limited Slip or Traction-Lok Differentials LB Chassis Grease, NLGI Classification LB LL Steering Linkage Lubricant LM Lithium Multipurpose Grease MA Mercon(r) Automatic Transmission Fluid MH Manifold Heat Riser Solvent MO Motor Oil, Any API Service Classification PC Carburetor Cleaner PS Power Steering Fluid SF Motor Oil, API service SF SG Motor Oil, API service SG SH Motor Oil, API service SH SLF Special Lubricant - Fluid SLS Special Lubricant - Spray WB Wheel Bearing Grease Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 6170 Fluid - A/T: Service and Repair Checking NOTE: Check the fluid level with the engine at normal operating temperature (the cooling fan comes on). 1. Park the car on level ground. Shut off the engine. 2. Remove the dipstick (yellow loop) from the transmission and wipe it with a clean cloth. 3. Insert the dipstick into the transmission. 4. Remove the dipstick and check the fluid level. It should be between the upper and lower marks. 5. If the level is below the lower mark, add fluid into the tube to bring it to the upper mark. Use Honda Premium Formula Automatic Transmission Fluid or an equivalent DEXRON® II Automatic Transmission Fluid (AT F) only. 6. Insert the dipstick back into the transmission. Changing Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 6171 1.Bring the transmission up to operating temperature by driving the car. Park the car on level ground, turn the engine off, then remove drain plug. 2.Reinstall the drain plug with a new washer, then refill the transmission to the upper mark on the dipstick. Automatic Transmission Fluid Capacity: 2.7 (2.9 US qt , 2.4 Imp at) at change 5.9 (6.2 US at , 5.2 Imp at) at overhaul Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Shift Interlock Control Module > Component Information > Locations Shift Interlock Control Module: Locations Behind Left Side Of Dash Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Torque Converter Oil Seal - Installation Tool Seals and Gaskets: Technical Service Bulletins Torque Converter Oil Seal - Installation Tool 00-022 March 7, 2000 Applies To: ALL Models With L4 or V6 Engine and A/T With 44 mm I.D. Torque Converter Oil Seal Torque Converter Oil Seal Installation Tool The service manual procedure for installing the torque converter oil seal requires you to disassemble the transmission. A new required special tool, which attaches to your existing 40 mm l.D. driver, lets you install this seal without removing the main shaft or disassembling the transmission. REQUIRED SPECIAL TOOLS Seal Driver Attachment: T/N O7XAD-001000A (Shipped to all dealers March 2000 as a required special tool) 40 mm I.D. Driver: T/N 07746-0030100 ORDERING INFORMATION Additional seal driver attachments are available from American Honda using normal parts ordering procedures. WARRANTY CLAIM INFORMATION None. This service bulletin is for information only. PROCEDURE 1. Remove the transmission (see section 14 of the appropriate service manual). 2. Remove and discard the torque converter oil seal. Be careful not to damage the torque converter housing. 3. Select the appropriate replacement seal. 4. Press the long end of the seal driver attachment into the driver. Press the new seal onto the short end. Do not apply any type of sealer to the seal or Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Torque Converter Oil Seal - Installation Tool > Page 6180 the torque converter housing; you must install the seal dry. 5. Slide the tool over the mainshaft as far as it will go. 6. With a soft-face hammer, lightly tap the driver until the seal is fully seated in the torque converter housing. 7. Reinstall the transmission. Disclaimer Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Shift Interlock Switch > Component Information > Locations Shift Interlock Switch: Locations Behind Left Side Of Dash Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > A/T Gear Position Signal <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Locations A/T Gear Position Signal: Locations Below Center Console Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > A/T Gear Position Signal <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Locations > Page 6188 A/T Gear Position Signal: Description and Operation PURPOSE This signals the Engine Control Module (ECM) when the Transmission is in Neutral or Park position. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > A/T Gear Position Signal <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Locations > Page 6189 A/T Gear Position Signal: Testing and Inspection Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > A/T Gear Position Signal <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Locations > Page 6190 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Control Module > Component Information > Locations Shift Interlock Control Module: Locations Behind Left Side Of Dash Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations Shift Interlock Solenoid: Locations Below Center Console Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations > Page 6198 Shift Interlock Solenoid: Testing and Inspection 1. Remove instrument panel lower cover and knee bolster. 2. Remove steering column upper and lower covers. 3. Disconnect shift lock solenoid 2-P connector. Fig. 13 Shift Lock Solenoid Test Terminal 4. Connect battery power momentarily to No. 1 terminal of shift lock solenoid, Fig. 13, noting the following: a. Ensure power is not applied to terminal No. 2, as the solenoid will be shorted out. b. Ensure shift lock stop does not protrude when in On position. c. Ensure shift lock stop does protrude more than 0.30 inches when Off. 5. Check that shift lock releases when release lever is pushed. 6. Check that shift lock solenoid locks when lever is released. 7. If solenoid does not work as outlined, replace. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations > Page 6199 Shift Interlock Solenoid: Service and Repair 1. Remove instrument panel lower cover and knee bolster. 2. Remove steering column upper and lower covers. 3. Disconnect 2-P electrical connector from shift lock solenoid. 4. Remove shift lock extension. Fig. 16 Shift Lock Solenoid Replacement 5. Remove screw and detent spring washer, Fig. 16. 6. Remove shift lock solenoid. 7. Reverse procedure to install, noting the following: a. Ensure shift lock stop does not protrude when solenoid is On. b. Ensure shift lock solenoid does protrude more than 0.30 inches when shift lock is Off. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Switch > Component Information > Locations Shift Interlock Switch: Locations Behind Left Side Of Dash Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments Shift Cable: Adjustments 1. With engine off, remove console. 2. Shift selector to Neutral position, then remove lockpin from cable adjuster, Fig. 14. 3. Ensure hole in adjuster is perfectly aligned with hole in shift cable. 4. If holes are not aligned, loosen locknut on shift cable and adjust as necessary. There are two holes in end of shift cable positioned 90 degrees apart to allow for small adjustments. 5. Tighten locknut, then install lockpin on adjuster. If lock pin binds during installation, cable is still out of adjustment. 6. Start engine and check shift lever in all gears. If any gear does not work, refer to Testing and Inspection / Procedures. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Adjustments Throttle Valve Cable/Linkage: Adjustments NOTE: Before adjusting the throttle control cable, make sure that: Throttle cable free play is correct. Idle speed is correct. You warm up the engine to normal operating temperature (the radiator fan comes on). 1. Verify that the throttle control cable is clamped correctly in three positions. 2. Verify that the throttle linkage is in the fully-closed position 3. Loosen the locknut on the throttle control cable at the throttle control lever. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Adjustments > Page 6210 4. Remove the free play in the throttle control cable with the locknut, while pushing the throttle control lever to the fully-closed position as shown. 5. Tighten lock nuts. 6. After tightening the locknuts, inspect the synchronization and throttle control lever movement. NOTE: To tailor the shift/lock-up characteristics to a particular customer's driving expectations, you can adjust the throttle control cable up to 2 mm (O.07B in) shorter than the "synchronized" point. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications Resistance ........................................................................................................................................... ............................... 14.1 - 15.5 Ohms at 25°C (77°F) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 6214 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 6215 Torque Converter Clutch Solenoid: Testing and Inspection NOTE: Lock-up control solenoid valves A and B must be removed/replaced as an assembly. 1. Disconnect the connector from the lock-up control solenoid valve A/B. 2. Measure the resistance between the No. 1 terminal (solenoid valve A) of the lock-up control solenoid valve connector and body ground, and between the No. 2 terminal (solenoid valve B) and body ground. Standard: 14.1 - 15.5 Ohms at 25°C (77°F) 3. Replace the lock-up control solenoid valve assembly if the resistance is out of specification. 4. Connect the No. 1 terminal of the lock-up control solenoid valve connector to the battery positive terminal and body ground. A clicking sound should be heard. Connect the No. 2 terminal to the battery positive terminal and body ground. A clicking sound should be heard. 5. If there is no clicking, check for continuity between the engine control module (ECM) A19 or A17 harness and body ground using the Test Harness: O7LAJ - PT3O1OA. NOTE: Always use the Test Harness (O7LAJ PT3O1OA) for checking. 6. Replace the lock-up control solenoid valve assembly if there is continuity between the ECM A19 or A17 harness and body ground. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 6216 Torque Converter Clutch Solenoid: Service and Repair 1. Remove the mounting bolts and lock-up control solenoid valve assembly. NOTE: Be sure to remove or replace the lock-up control solenoid valves A and B as an assembly. 2. Check the lock-up control solenoid valve oil passages for dust or dirt, and replace as an assembly, if necessary. 3. Clean the mounting surface and oil passages of the lock-up control solenoid valve assembly and install a new filter/gasket. 4. Check the connector for rust, dirt or oil and reconnect it securely. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - ATF Cooler Cleaner Information Transmission Cooler: Technical Service Bulletins A/T - ATF Cooler Cleaner Information Use Worm-Style Clamps With the ATF Cooler Cleaner The spring-style clamps used on the ATF cooler lines are made to hold the cooler lines to the ATF cooler under normal operating conditions. The ATF Cooler Cleaner (P/N GHTTTCF6H) uses high pressure (100 psi) to do its job. With the pump motor running, the spring-style clamps can walk off or disconnect, and you'll wind up with a real mess to clean up in your shop. In March of this year, we sent each Honda dealership a pair of high-quality worm-style clamps to replace the original spring-style clamps. These clamps were part of a cooler cleaner update kit, and securely hold the cooler line in place. They've got a blue cap for easy identification. Need some more? Just call G-TFC, Inc. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - ATF Cooler Cleaner Information > Page 6221 Transmission Cooler: Technical Service Bulletins A/T - Cooler Flushing Equipment Information 89-022 May 16, 2008 Applies To: Vehicles With an In-Radiator ATF Cooler - ALL ATF Cooler Cleaner (Supersedes 89-022, dated June 18, 2004, to update the information marked by asterisks) Before installing an overhauled or remanufactured A/T, you must thoroughly clean the ATF cooler to prevent system contamination. Failure to do so could cause a repeat A/T failure. The ATF Cooler Cleaner (PIN GTHTTCF6H) is a portable, electrically operated special tool that cleans the ATF cooler with high- pressure, heated ATF. This cleaning action melts down waxy varnish residue left by burnt ATF and purges metal particles, clutch material, and other contaminants. The ATF Cooler Cleaner has these features: ^ Quick-connect fittings and color-coded hoses for easy hookup. ^ Uses about 9.5 gallons of Honda ATF-Z1, which gets filtered and recirculated. ^ Heats ATF to a temperature of 1400 to 150°F and then pumps it through the ATF cooler at high pressure (100 psi) using a pulsating action and air purging. Switching the hoses cleans the ATF cooler in the reverse direction. ^ Two magnetic nonbypass spin-on filters to trap purged contaminants. ^ Built-in tool tray. This service bulletin gives you information for ordering and servicing this special tool, and guides you through the entire ATF cooler cleaning process. *REQUIRED MATERIALS Honda ATF-Z1: P/N 08200-9001 Magnetic Nonbypass Spin-On Filter: T/N GTHNBP12 (12-pack) T/N GTHNBP2 (6-pack) T/N GTHGNBP22 (2-pack) ORDERING INFORMATION Additional ATF cooler cleaners or magnetic nonbypass spin-on filters can be ordered through the Honda Tool and Equipment Program. To order on the iN, click on SERVICE, then Service Bay, then Tool and Equipment Program. From the Tool and Equipment Program menu, click on the Online Catalog tab, and then search for the desired filter pack by part number.* Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - ATF Cooler Cleaner Information > Page 6222 TOOL DESCRIPTION CLEANING PROCEDURE The cleaning procedure involves hot fluid under high pressure. Check the security of all hoses and connections. Always wear safety glasses or a face shield, gloves, and protective clothing. If you get ATF in your eyes or on your skin, rinse with water immediately. Improper use of the ATF cooler cleaner can result in burns and other serious injuries. Always wear eye protection and protective clothing, and follow all instructions in this bulletin. 1. Plug the ATF cooler cleaner into a 110 V grounded electrical outlet. NOTICE Make sure the outlet has no other appliances (light fixtures, drop lights, extension cords) plugged into it. Also, never plug the cooler cleaner into an extension cord or drop light cord; you would damage the unit. 2. Flip the HEAT toggle switch to ON. Wait 1 hour for the cooler cleaner to reach its operating temperature. (The cooler cleaner is ready to use when the temperature gauge reads 140° to 150°F.) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - ATF Cooler Cleaner Information > Page 6223 3. Connect the appropriate fittings to the ATF cooler inlet and outlet lines. Connect the red hose to the cooler outlet line (the line going to the external filter). Connect the blue hose to the cooler inlet line. 4. Connect a shop air hose to the air purge valve. NOTICE The quick connect fitting has a one-way check valve to keep ATF from entering your shop's air system. Do not remove or replace the fitting. Attach the coupler provided with the cooler cleaner to your shop air line if your coupler is not compatible. 5. Flip the MOTOR toggle switch to ON, and let the pump run for 5 minutes. While the pump is running, open and close the air purge valve periodically to cause agitation and improve the cleaning process. 6. Flip the MOTOR toggle switch to OFF with the air purge valve open. Leave the air purge valve open for at least 15 seconds to purge the lines of residual ATF. 7. Disconnect the red and blue hoses from the ATF cooler, then connect the red hose to the cooler inlet line. 8. Connect the blue hose to the cooler outlet line. 9. Flip the MOTOR toggle switch to ON, and let the pump run for 5 minutes. While the pump is running, open and close the air purge valve periodically. 10. Flip the MOTOR toggle switch to OFF with the air purge valve open. Leave the air purge valve open for at least 15 seconds to purge the lines of residual ATF. 11. Disconnect the red and blue hoses from the ATF cooler lines. Connect the red and blue hoses to each other. 12. Disconnect the shop air from the air purge valve. Disconnect and stow the coupler if used. 13. Disconnect and stow the fittings from the ATF cooler inlet and outlet lines. 14. Unplug the cooler cleaner from the 110 V outlet. TOOL MAINTENANCE Follow these instructions to keep the ATF cooler cleaner working properly: *^ Replace the two magnetic nonbypass spin-on filters every 20 hours, based on hour meter reading. For more information on filter replacement, see the January 2008 Honda ServiceNews article, Hour Meter Tells You When to Replace ATF Cooler Cleaner Filters.* ^ Fill the tank so the ATF is 4.5 inches from the top of the filler hole; do not overfill. NOTE: If the fluid level is low, the red indicator above the HEAT toggle switch comes on and the tank heater will not work. ^ Replace the ATF in the tank when it looks dark or dirty. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - ATF Cooler Cleaner Information > Page 6224 Disclaimer Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > A/T Gear Position Signal <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Locations A/T Gear Position Signal: Locations Below Center Console Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > A/T Gear Position Signal <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Locations > Page 6228 A/T Gear Position Signal: Description and Operation PURPOSE This signals the Engine Control Module (ECM) when the Transmission is in Neutral or Park position. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > A/T Gear Position Signal <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Locations > Page 6229 A/T Gear Position Signal: Testing and Inspection Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > A/T Gear Position Signal <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Locations > Page 6230 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Diagrams Valve Body: Diagrams Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Diagrams > Page 6234 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair Clutch Master Cylinder: Service and Repair 1. Remove fluid with syringe, disconnect clutch pipe and reservoir hose from master cylinder, then plug clutch pipe and reservoir hose. 2. Pry out cotter pin and remove pedal pin yoke, then remove nuts and master cylinder. 3. Reverse procedure to install. Bleed hydraulic system. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Service and Repair Clutch Slave Cylinder: Service and Repair 1. Disconnect and plug clutch hydraulic hose from slave cylinder. 2. Remove slave cylinder to clutch housing attaching bolts, then slave cylinder. 3. Reverse procedure to install. Bleed hydraulic system. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Locations Clutch Switch: Locations Behind Left Side Of Dash Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Testing and Inspection > Hitachi Starters Clutch Switch: Testing and Inspection Hitachi Starters 1. Remove instrument panel lower cover and left knee bolster. 2. Disconnect connector from switch. 3. With clutch pedal released, check continuity between both terminals. No continuity should be found. If continuity is found, replace or adjust switch as necessary. 4. With clutch pedal depressed, check continuity between both terminals. Continuity should be found. If no continuity is found, replace or adjust switch as necessary. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Testing and Inspection > Hitachi Starters > Page 6248 Clutch Switch: Testing and Inspection Mitsuba Starters 1. Remove instrument panel lower cover and left knee bolster. 2. Disconnect connector from switch. 3. With clutch pedal released, check continuity between both terminals. No continuity should be found. If continuity is found, replace or adjust switch as necessary. 4. With clutch pedal depressed, check continuity between both terminals. Continuity should be found. If no continuity is found, replace or adjust switch as necessary. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Testing and Inspection > Hitachi Starters > Page 6249 Clutch Switch: Testing and Inspection Nippondenso Starters 1. Remove instrument panel lower cover and left knee bolster. 2. Disconnect connector from switch. 3. With clutch pedal released, check continuity between both terminals. No continuity should be found. If continuity is found, replace or adjust switch as necessary. 4. With clutch pedal depressed, check continuity between both terminals. Continuity should be found. If no continuity is found, replace or adjust switch as necessary. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Transmission Cooler, CVT > Component Information > Technical Service Bulletins > A/T - ATF Cooler Cleaner Information Transmission Cooler: Technical Service Bulletins A/T - ATF Cooler Cleaner Information Use Worm-Style Clamps With the ATF Cooler Cleaner The spring-style clamps used on the ATF cooler lines are made to hold the cooler lines to the ATF cooler under normal operating conditions. The ATF Cooler Cleaner (P/N GHTTTCF6H) uses high pressure (100 psi) to do its job. With the pump motor running, the spring-style clamps can walk off or disconnect, and you'll wind up with a real mess to clean up in your shop. In March of this year, we sent each Honda dealership a pair of high-quality worm-style clamps to replace the original spring-style clamps. These clamps were part of a cooler cleaner update kit, and securely hold the cooler line in place. They've got a blue cap for easy identification. Need some more? Just call G-TFC, Inc. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications Axle Shaft: Specifications Component .......................................................................................................................................... ....................................................... Torque/Ft. Lbs. Spindle Nut ......................................................... ............................................................................................................................................................. 134 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 6260 Axle Shaft: Service and Repair NOTE: Replacement procedures for left and right driveshafts are the same. 1. Raise and support front of vehicle, then remove front wheels. 2. Drain transaxle. 3. Raise locking tab on spindle nut, then remove nut. 4. Remove damper fork, then the cotter pin from lower arm ball joint castle nut and remove nut. 5. Install hex nut on ball joint. Ensure nut is flush with ball joint pin end, or threaded section of ball joint pin might be damaged by ball joint remover. 6. Separate ball joint and lower arm using ball joint remover tool No. 07MAC-SL00100, or equivalent. Be careful not to damage ball joint boot. 7. Pry driveshaft assembly with screwdriver to force set ring at driveshaft end past groove. 8. Pull on inboard joint and remove driveshaft from differential case or bearing support as an assembly. Do not pull on driveshaft, as inboard joint may come apart. Use care when prying out assembly, and pull it straight to avoid damaging differential oil seal or intermediate shaft outer seal. 9. Pull knuckle outward and remove driveshaft outboard joint from front wheel hub using plastic hammer. 10. Reverse procedure to install. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Technical Service Bulletins > Customer Interest for Constant Velocity Joint: > 91-029 > Jan > 99 > Drivetrain - Clicking Noise On Low Speed Turns Constant Velocity Joint: Customer Interest Drivetrain - Clicking Noise On Low Speed Turns 91-029 January 26, 1999 Applies To: ALL 1988 and later Models* Clicking Noise While Turning (Supersedes 91-029, dated April 17, 1992) Updated information is shown with asterisks and black bars. SYMPTOM A clicking noise is heard while making right or left turns at 10 mph or less. PROBABLE CAUSE Worn outboard driveshaft joint. CORRECTIVE ACTION Replace the noisy outboard driveshaft joint. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. Defect code: 042 Contention code: B07 Failed part: Use the replacement Part Number Skill level: Repair Technician PARTS INFORMATION REQUIRED SPECIAL TOOLS DIAGNOSIS (Driving method) 1. Drive the car in a circle in an open parking lot at approximately 10 mph with the brakes slightly applied. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Technical Service Bulletins > Customer Interest for Constant Velocity Joint: > 91-029 > Jan > 99 > Drivetrain - Clicking Noise On Low Speed Turns > Page 6269 2. Have an assistant stand in the center of the circle and listen for the clicking noise. 3. Drive the car in the opposite direction. The assistant should be able to tell which axle is making the noise. DIAGNOSIS (On-hoist method) 1. Raise the car on a hoist and start the engine. 2. With the transmission in first gear (manual transmission) or D4 (automatic transmission), increase the engine speed to 2,000 rpm. 3. Apply the brakes to load the engine speed to 1,500 rpm while maintaining the same throttle position. 4. Turn the wheels slowly to full left and full right positions. Have an assistant listen to determine which axle is making the noise. NOTE: A driveshaft with a light degree of noise may not be detected by this on-hoist method. REPAIR PROCEDURE 1. Remove the driveshaft as described in Section 16 of the appropriate service manual. 2. Use diagonal cutters to cut the two boot bands and the outboard joint boot, then remove them from the driveshaft. 3. Wipe off the grease to expose the outboard joint. Measure and record distance "A" (from the splined end of the driveshaft to the inner race) as a reference for reassembly. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Technical Service Bulletins > Customer Interest for Constant Velocity Joint: > 91-029 > Jan > 99 > Drivetrain - Clicking Noise On Low Speed Turns > Page 6270 4. Carefully clamp the driveshaft in a vise. 5. *Remove the outboard joint using the threaded adapter (see REQUIRED SPECIAL TOOLS) and a commercially available 5/8" x 18 slide hammer.* 6. Remove and discard the "C" clip from the driveshaft. Clean and inspect the driveshaft splines and ring groove for burrs or other defects. 7. Install the new outboard joint boot provided in the kit. Slide it slowly onto the driveshaft to avoid damaging the boot. 8. Install the new "C" clip onto the ring groove of the driveshaft. 9. Insert the driveshaft in the new outboard joint. Make sure the "C" clip is centered on the shaft and is resting against the chamfered edge of the inner race. 10. Remove the driveshaft from the vise. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Technical Service Bulletins > Customer Interest for Constant Velocity Joint: > 91-029 > Jan > 99 > Drivetrain - Clicking Noise On Low Speed Turns > Page 6271 11. To drive the outboard joint on the rest of the way, pick up the assembly and let it fall from about 10 cm (4 to 5 in.) onto a hard surface. NOTICE Do not use a hammer; excessive force may damage the driveshaft. 12. Measure distance "A" (from the splines to the inner race of the joint). If the distance is more than your measurement in Step 3, repeat Step 11. 13. When distance "A" equals your measurement in Step 3, the "C" clip should be seated in the joint. Tap on the inner race with a plastic hammer to make sure the joint does not move on the driveshaft. 14. Fit the small end of the boot into the boot groove on the driveshaft. 15. Install the small boot band provided in the kit. Bend both sets of locking tabs over, then lightly tap them flat. 16. Pack the outboard boot with the grease included in the kit. Pack the outboard joint with the remaining grease, then fit the boot over the outboard joint. 17. Install the large boot band provided in the kit. Bend both sets of locking tabs over, then lightly tap them flat. 18. Reinstall the driveshaft assembly into the car. Refer to Section 16 of the appropriate service manual. Disclaimer Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Constant Velocity Joint: > 91-029 > Jan > 99 > Drivetrain - Clicking Noise On Low Speed Turns Constant Velocity Joint: All Technical Service Bulletins Drivetrain - Clicking Noise On Low Speed Turns 91-029 January 26, 1999 Applies To: ALL 1988 and later Models* Clicking Noise While Turning (Supersedes 91-029, dated April 17, 1992) Updated information is shown with asterisks and black bars. SYMPTOM A clicking noise is heard while making right or left turns at 10 mph or less. PROBABLE CAUSE Worn outboard driveshaft joint. CORRECTIVE ACTION Replace the noisy outboard driveshaft joint. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. Defect code: 042 Contention code: B07 Failed part: Use the replacement Part Number Skill level: Repair Technician PARTS INFORMATION REQUIRED SPECIAL TOOLS DIAGNOSIS (Driving method) 1. Drive the car in a circle in an open parking lot at approximately 10 mph with the brakes slightly applied. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Constant Velocity Joint: > 91-029 > Jan > 99 > Drivetrain - Clicking Noise On Low Speed Turns > Page 6277 2. Have an assistant stand in the center of the circle and listen for the clicking noise. 3. Drive the car in the opposite direction. The assistant should be able to tell which axle is making the noise. DIAGNOSIS (On-hoist method) 1. Raise the car on a hoist and start the engine. 2. With the transmission in first gear (manual transmission) or D4 (automatic transmission), increase the engine speed to 2,000 rpm. 3. Apply the brakes to load the engine speed to 1,500 rpm while maintaining the same throttle position. 4. Turn the wheels slowly to full left and full right positions. Have an assistant listen to determine which axle is making the noise. NOTE: A driveshaft with a light degree of noise may not be detected by this on-hoist method. REPAIR PROCEDURE 1. Remove the driveshaft as described in Section 16 of the appropriate service manual. 2. Use diagonal cutters to cut the two boot bands and the outboard joint boot, then remove them from the driveshaft. 3. Wipe off the grease to expose the outboard joint. Measure and record distance "A" (from the splined end of the driveshaft to the inner race) as a reference for reassembly. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Constant Velocity Joint: > 91-029 > Jan > 99 > Drivetrain - Clicking Noise On Low Speed Turns > Page 6278 4. Carefully clamp the driveshaft in a vise. 5. *Remove the outboard joint using the threaded adapter (see REQUIRED SPECIAL TOOLS) and a commercially available 5/8" x 18 slide hammer.* 6. Remove and discard the "C" clip from the driveshaft. Clean and inspect the driveshaft splines and ring groove for burrs or other defects. 7. Install the new outboard joint boot provided in the kit. Slide it slowly onto the driveshaft to avoid damaging the boot. 8. Install the new "C" clip onto the ring groove of the driveshaft. 9. Insert the driveshaft in the new outboard joint. Make sure the "C" clip is centered on the shaft and is resting against the chamfered edge of the inner race. 10. Remove the driveshaft from the vise. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Constant Velocity Joint: > 91-029 > Jan > 99 > Drivetrain - Clicking Noise On Low Speed Turns > Page 6279 11. To drive the outboard joint on the rest of the way, pick up the assembly and let it fall from about 10 cm (4 to 5 in.) onto a hard surface. NOTICE Do not use a hammer; excessive force may damage the driveshaft. 12. Measure distance "A" (from the splines to the inner race of the joint). If the distance is more than your measurement in Step 3, repeat Step 11. 13. When distance "A" equals your measurement in Step 3, the "C" clip should be seated in the joint. Tap on the inner race with a plastic hammer to make sure the joint does not move on the driveshaft. 14. Fit the small end of the boot into the boot groove on the driveshaft. 15. Install the small boot band provided in the kit. Bend both sets of locking tabs over, then lightly tap them flat. 16. Pack the outboard boot with the grease included in the kit. Pack the outboard joint with the remaining grease, then fit the boot over the outboard joint. 17. Install the large boot band provided in the kit. Bend both sets of locking tabs over, then lightly tap them flat. 18. Reinstall the driveshaft assembly into the car. Refer to Section 16 of the appropriate service manual. Disclaimer Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Technical Service Bulletins > Page 6280 Constant Velocity Joint: Service and Repair Fig. 1 Front Drive Assembly NOTE: Prior to disassemble, mark rollers and roller grooves. Refer to Fig. 1 for driveshaft service. 1. Remove set ring from inboard joint. 2. Remove boot band by prying up locking tabs with screwdriver and raising end of band. 3. Remove inboard joint, then remove rollers from spider. 4. Remove circlip, then the spider from shaft using suitable bearing remover. 5. Remove stopper ring. 6. Wrap splines on driveshaft with vinyl tape to prevent damaging boots and dynamic damper, then remove boot band and inboard boot. 7. Remove dynamic damper band and dynamic damper. 8. Remove boot bands and outboard boot, then the vinyl tape. 9. Reverse procedure to install, noting the following: a. Pack inboard and outboard joints with molybdenum disulfide grease. b. Install rollers on spider shafts, then slide spider assembly into inboard shaft joint. Avoid getting grease on rubber parts. c. Position boots and install small end bands, then expand and compress boots until they return to their normal shape and length. d. Install large end bands. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Technical Service Bulletins > Drivetrain - Revised CV Joint Boot Band/Installation Constant Velocity Joint Boot: Technical Service Bulletins Drivetrain - Revised CV Joint Boot Band/Installation 98-018 July 22, 2003 Applies To: ALL Models Driveshaft Boot Band Tool (Supersedes 98-018, Boot Band Tool, dated April 14, 1998) Updated information is shown by asterisks. The replacement boot bands for the driveshaft CV joint boots have changed. The replacement bands are a double loop type that require a special tool for proper installation. * TOOL INFORMATION Boot Band Tool: T/N KD-3191 This tool is already at your dealership. To order additional tools, call the Honda Tool and Equipment Program at 1-888-424-6857. Phone lines are open Monday through Friday from 7:30 a.m. to 7:00 p.m. CT.* REPAIR PROCEDURE 1. Remove the old boot band(s). Take care not to damage the boot. 2. Remove and inspect the boot. Replace the boot if it is worn or damaged. 3. Install the boot, and fill it with the specified amount and type of grease. Refer to section 16 of the appropriate service manual for the grease amount and type. 4. Adjust the driveshaft to the proper length. Refer to section 16 of the appropriate service manual. 5. Install the replacement boot band onto the large end of the boot with the end of the band facing toward the front of the vehicle. 6. Take up the slack in the boot band by hand, and hold the boot band in place. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Technical Service Bulletins > Drivetrain - Revised CV Joint Boot Band/Installation > Page 6285 7. Measure and mark the band with a felt-tip pen at the specified distance from the clip: ^ If you are installing a new boot, mark the band approximately 10 to 14 mm (0.4 to 0.6 in.) from the clip. ^ If you are reinstalling the original boot, mark the band 10 mm (0.4 in.) from the clip. 8. Thread the free end of the band through the nose section of the boot band tool and into the slot on the winding mandrel. 9. Take up the slack in the boot band by hand, then slowly turn the winding mandrel with a wrench. Tighten the band until the mark you made in step 7 meets the edge of the clip. 10. Raise up the boot band tool to bend the free end of the band 90 degrees, then center-punch the clip to hold the band temporarily. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Technical Service Bulletins > Drivetrain - Revised CV Joint Boot Band/Installation > Page 6286 11. Unwind the boot band tool, and cut off the excess 5 to 10 mm (0.2 to 0.4 in.) from the clip. 12. Secure the end of the boot band by tapping it down over the clip with a hammer. 13. Make sure that the boot band and clip do not interfere with anything and that the band does not move. 14. If necessary, repeat steps 5 through 13 to install the boot band on the small end of the boot. Disclaimer Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Adjustments Wheel Bearing: Adjustments Wheel bearings and hub on these models are an integral assembly and bearings cannot be adjusted. If hub endplay exceeds 0.002 inch with spindle nut properly tightened, hub and bearing assembly should be replaced. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension Wheel Bearing: Service and Repair Front Suspension 1. Raise and support front of vehicle, then remove front wheels. 2. Raise spindle nut locking tab, then remove spindle nut. 3. Remove brake hose bracket mounting bolts. 4. Remove caliper and position aside. Do not allow caliper assembly to hang from brake hose. 5. Remove brake disc attaching screws, then thread two 8 x 1.25 x 12 mm bolts into attaching screw holes to push disc from hub. When tightening screws, turn only two turns at a time to prevent excessively cocking the brake disc. 6. Remove brake disc from knuckle. 7. Remove speed sensor wire bracket, then the speed sensor from knuckle. 8. Remove tie rod end cotter pin and nut. 9. Remove tie rod end using suitable tie rod end remover. 10. Remove lower ball joint cotter pin, then loosen ball joint nut half way. 11. Using ball joint remover tool No. 07MAC-SL00200, or equivalent, separate ball joint and lower arm. 12. Remove upper ball joint shield, then the cotter pin and nut. 13. Separate upper ball joint from upper arm using suitable ball joint remover. 14. Remove steering knuckle and hub assembly by sliding off driveshaft. 15. Remove hub from steering knuckle using suitable press. 16. Remove knuckle ring, circlip and splash guard from knuckle. 17. Press out wheel bearing from hub using driver tool No. 07749-0010000, attachment tool No. 07746-0010500 and base tool No. 07GAF-SE00401, or equivalents. 18. Remove outboard bearing inner race from hub. Fig. 4 Front Suspension 19. Reverse procedure to install. Refer to Fig. 2 for tightening specifications. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 6292 Wheel Bearing: Service and Repair Rear Suspension Disc Brake Models 1. Raise and support vehicle, then remove rear wheels. 2. Apply parking brake, then remove hub cap. 3. Raise locking tab on spindle nut, then remove nut. 4. Remove 6 mm brake disc retaining screw, then the caliper shield. 5. Remove brake hose mounting bolts, then the caliper bracket mounting bolts. 6. Remove caliper and hang from undercarriage with short piece of wire. Do not hang caliper by brake hose. 7. Screw two 12 mm bolts into disc to push disc off of hub. Remove disc. 8. Remove hub unit from knuckle. 9. Reverse procedure to install. Drum Brake Models 1. Raise and support rear of vehicle, then remove wheel and brake drum. 2. Remove grease cap, spindle nut and washer. 3. Remove hub and bearing unit from spindle. 4. Reverse procedure to install. Tighten spindle nut to specifications, then stake shoulder of nut into groove in spindle. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Component .......................................................................................................................................... .......................................................... Torque/Ft. Lbs. Spindle Nut ...................................................... .............................................................................................................................................................. .. 134 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications Flex Plate: Specifications For the Specifications for Flex Plate, go to Engine/Specifications. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications Flywheel: Specifications Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications > Page 6303 Flywheel: Testing and Inspection 1. Inspect the ring gear teeth for wear and damage. 2. Inspect the clutch disc mating surface on the flywheel for wear, cracks, and burning. 3. Measure the flywheel runout using a dial indicator through at least two full turns. Push against the flywheel each time you turn it to take up the crankshaft thrust washer clearance. NOTE: The runout can be measured with engine installed. Standard (New): 0.05 mm (0.002 inch) max. Service Limit: 0.15 mm (0.006 inch) If the runout exceeds the service limit, replace the flywheel. 4. Turn the inner race of the ball bearing with your finger. The bail bearing should turn smoothly and quietly. Check that the ball bearing outer race fits tightly in the flywheel. If the inner race does not turn smoothly, quietly, or fit tight in the flywheel, replace the ball bearing. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Bell Housing, M/T > Component Information > Service and Repair Bell Housing: Service and Repair Mainshaft 1. Remove the ball bearing using the special tools. 2. Remove the oil seal from the clutch housing. 3. Drive the new oil seal into the clutch housing using the special tools as shown. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Bell Housing, M/T > Component Information > Service and Repair > Page 6308 4. Drive the ball bearing with the shielded side down into the clutch housing using the special tools as shown. Countershaft 1. Remove the needle bearing using the special tools. then remove the oil guide plate. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Bell Housing, M/T > Component Information > Service and Repair > Page 6309 2. Install the oil guide plate, then drive the needle bearing into the clutch housing using the special tools as shown. NOTE: Position the needle bearing with the oil hole facing up. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Case, M/T > Component Information > Service and Repair Case: Service and Repair NOTE: Place the clutch housing on two pieces of wood thick enough to keep the mainshaft from the hitting the workbench. 1. Remove the back-up light switch. 2. Remove the transmission hanger B. 3. Loosen the transmission housing attaching bolts in a crisscross pattern in several steps, then remove them. 4. Remove the 32 mm sealing bolt. 5. Expand the snap ring on the countershaft ball bearing and remove it from the groove using a pair of snap ring plier. 6. Separate the transmission housing from the clutch housing and wipe it clean of the sealant. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Case, M/T > Component Information > Service and Repair > Page 6313 7. Remove the thrust shim and oil guide plate from the transmission housing. 8. Remove the 10 mm sealing bolt and oil gutter plate. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Countershaft, M/T > Component Information > Service and Repair > Index Countershaft: Service and Repair Index NOTE: The 3rd, 4th, and 5th gears are installed with a press. Prior to reassembling, clean all the parts in solvent, dry them and apply lubricant to any contact surfaces. The 3rd, 4th, and 5th gears, however, should be installed with a press before lubricating them. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Countershaft, M/T > Component Information > Service and Repair > Index > Page 6318 Countershaft: Service and Repair Clearance Inspection NOTE: If replacement is required, always replace the synchro sleeve set. 1. Measure the clearance between the countershaft and 1st gear. Standard: 0.03-0.10 mm (0.001-0.004 in) Service Limit: 0.22 mm (0.009 in) 2. If the clearance exceeds the service limit, measure the thickness of 1st gear. If the thickness of 1st gear is less than the service limit, replace 1st gear with a new one. If the thickness of 1st gear is within the service limit, replace the 1st/2nd synchro hub with a new one. 3. Measure the clearance between 2nd and 3rd gears. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Countershaft, M/T > Component Information > Service and Repair > Index > Page 6319 4. If the clearance exceeds the service limit, measure the thickness of the spacer collar. 5. If the thickness is less than the service limit, replace the spacer collar with a new one. If the thickness is within the service limit, measure the thickness of 2nd gear. If the thickness of 2nd gear is less than the service limit, replace 2nd gear with a new one. If the thickness of 2nd gear is within the service limit, replace the spacer collar with a new one. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Countershaft, M/T > Component Information > Service and Repair > Index > Page 6320 Countershaft: Service and Repair Disassembly CAUTION: Remove the gears using a press and steel blocks as shown. Use of a jaw-type puller can damage the gear teeth. 1. Securely clamp the countershaft assembly in a bench vise with wood blocks. 2. Raise the locknut tab from the groove of the countershaft, then remove the locknut and the spring washer. 3. Remove the bearings using a bearing puller as shown. 4. Support 4th gear on steel blocks as shown and press the countershaft out of 5th and 4th gears. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Countershaft, M/T > Component Information > Service and Repair > Index > Page 6321 5. Support 1st gear on steel blocks as shown and press the countershaft out of 3rd gear. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Countershaft, M/T > Component Information > Service and Repair > Index > Page 6322 Countershaft: Service and Repair Inspection 1. Inspect the gear surfaces and bearing surfaces for wear and damage, then measure the countershaft at points A, B, and C. If any part of the countershaft is less than the service limit, replace it with a new one. 2. Inspect for runout. If the runout exceeds the service limit, replace the countershaft with a new one. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Countershaft, M/T > Component Information > Service and Repair > Index > Page 6323 Countershaft: Service and Repair Reassembly CAUTION: - Press the 3rd, 4th, and 5th gears on the countershaft without lubrication. - When installing the 3rd. 4th, and 5th gears, support the shaft on steel blocks and install the gears using a press. 1. Install the needle bearing on the countershaft. 2. Assemble the parts as shown in image. NOTE: Check that the fingers of the friction damper are securely set in the grooves of the 1st/2nd synchro hub. 3. Install the parts on the countershaft. 4. Support the countershaft on a steel block as shown and install 3rd gear using the special tools and a press as shown. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Countershaft, M/T > Component Information > Service and Repair > Index > Page 6324 5. Install 4th gear using the special tools and a press as shown. 6. Install 5th gear using the special tools and a press as shown. 7. Install the bearings using the special tools and a press as shown. 8. Securely clamp the countershaft assembly in a bench vise with wood blocks. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Countershaft, M/T > Component Information > Service and Repair > Index > Page 6325 9. Install the spring washer, tighten the locknut, then stake the locknut tab into groove. LOCKNUT 110 -> 0 -> 110 N.m (11.0 -> 0 -> 11.0 kg-m, 80 -> 0 ->80 lb-ft) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Ring Gear, M/T > Component Information > Specifications Ring Gear: Specifications TIGHTENING SPECIFICATIONS Bolts ..................................................................................................................................................... ........................................... 101 Nm (74.5 ft. lbs.) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications TYPE 1992-95 ..................................................................................................................................... ............................................................................. SG TYPE 1996 .......................................................................................................................................... ........................................................................... GLS Above 20°F (-7°C), 1992 ..................................................................................................................... .............................................................................. 30 Above 0°F (-18°C), 1992 ................................. ......................................................................................................................................................... 20W-40 All temperatures ..................................................................................................................... ................................................................ 10W-30*, 10W-40* * Preferred CAPACITY, Refill: Accord ................................................................................................................................................. ............................................ 1.9 liters 4.0 pints Civic, Del Sol ....................................................................................................................................... ........................................... 1.8 liters 3.8 pints VTEC 1992-95...................................................................................................................................... ..................................... 2.2 liters 4.6 pints Prelude ................................................................................................................................................ ............................................ 1.9 liters 4.0 pints Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 6334 Fluid - M/T: Fluid Type Specifications KEY TO LUBRICATION ABBREVIATIONS NOTE: Some manufacturer lubricant names may differ from the following list. If the manufacturer does not recommend a specific lubricant, use the following. AF Dexron(r)-III Automatic Transmission Fluid AP ATF-PLUS(r) Automatic Transmission Fluid BJ Suspension Lubricant BL Brake Lubricant CC Motor Oil, API Service CC CD Motor Oil, API Service CD CE Motor Oil, API Service CE CF-4 Motor Oil, API Service CF-4 DC Distributor Cam Lubricant EC Ethylene Glycol Coolant EP Extreme Pressure Gear Oil FA Automatic Transmission Fluid, Type F GC Wheel Bearing Grease, NLGI Classification GC GF-1 Motor Oil, API Service GF-1 (Starburst) GL-1 Gear Oil, API Service GL-1 GL-4 Gear Oil, API Service GL-4 GL-5 Gear Oil, API Service GL-5 GL-5* GL-5 Gear Oil for Limited Slip Differentials GLS Gear Lubricant, Special HB Hydraulic Brake Fluid, SAE J1703, DOT-3 or 4 HBH Hydraulic Brake Fluid, Extra Heavy Duty HG High Temperature Grease HP Hypoid Gear Oil HP* Hypoid Gear Oil for Limited Slip or Traction-Lok Differentials LB Chassis Grease, NLGI Classification LB LL Steering Linkage Lubricant LM Lithium Multipurpose Grease MA Mercon(r) Automatic Transmission Fluid MH Manifold Heat Riser Solvent MO Motor Oil, Any API Service Classification PC Carburetor Cleaner PS Power Steering Fluid SF Motor Oil, API service SF SG Motor Oil, API service SG SH Motor Oil, API service SH SLF Special Lubricant - Fluid SLS Special Lubricant - Spray WB Wheel Bearing Grease Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Page 6335 Fluid - M/T: Service and Repair NOTE: Check the oil with the engine OFF, and the car on level ground. 1. Remove the oil filler plug, then check the level and condition of the oil. 2. The oil level must be up to the filler hole. If it is below the hole, add oil until it runs out, then reinstall the oil filler plug. 3. If the transmission oil is dirty, remove the drain plug and drain the oil. 4. Reinstall the drain plug with a new washer, and refill the transmission oil to the proper level. NOTE: The drain plug washer should be replaced at every oil change. 5. Reinstall the oil filler plug with a new washer. Oil Capacity 1.8l (1.9 US qt, 1.6 Imp qt) at oil change. 1.9l (2.0 US qt, 1.7 Imp qt) at overhaul. Use only SAE 1OW-30 or 1OW-40, SF or SG grade. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Gear, M/T > Synchronizer Hub, M/T > Component Information > Testing and Inspection Synchronizer Hub: Testing and Inspection 1. Inspect gear teeth on all synchro hubs and synchro sleeves for rounded off corners, which indicate wear. 2. Install each synchro hub in its mating synchro sleeve and check for freedom of movement. NOTE: If replacement is required, always replace the synchro sleeve and synchro hub as a set. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Gear, M/T > Synchronizer Hub, M/T > Component Information > Testing and Inspection > Page 6340 Synchronizer Hub: Service and Repair Each synchro sleeve has three sets of longer teeth (120 degrees apart) that must be matched with the three sets of deeper grooves in the synchro hub when assembled. NOTE: Installing the synchro sleeve with its longer teeth in the synchro hub slots will damage the spring ring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Gear, M/T > Synchronizer Ring, M/T > Component Information > Service and Repair Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Mainshaft, M/T > Component Information > Testing and Inspection > Inspection Mainshaft: Testing and Inspection Inspection 1. Inspect the gear surface and bearing surface for wear and damage, then measure the mainshaft at points A, B, C, and D. If any part of the mainshaft is less than the service limit, replace it with a new one. 2. Inspect for runout. If the runout exceeds the service limit, replace the mainshaft with a new one. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Mainshaft, M/T > Component Information > Testing and Inspection > Inspection > Page 6348 Mainshaft: Testing and Inspection Clearance Inspection NOTE: If replacement is required, always replace the synchro sleeve set. 1. Measure the clearance between 2nd and 3rd gears. 2. If the clearance exceeds the service limit, measure the thickness of 3rd gear. If the thickness of 3rd gear is less than the service limit, replace 3rd gear with a new one. If the thickness of 3rd gear is within the service limit, replace the 3rd/4th synchro hub with a new one. 3. Measure the clearance between 4th gear and the spacer collar. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Mainshaft, M/T > Component Information > Testing and Inspection > Inspection > Page 6349 4. If the clearance exceeds the service limit, measure distance (A) on the spacer collar. 5. If distance (A) is less than the service limit, replace the spacer collar with a new one. If distance (A) is within the service limit, measure the thickness of 4th gear. If the thickness of 4th gear is less than the service limit, replace 4th gear with a new one. If the thickness of 4th gear is within the service limit, replace the 3rd/4th synchro hub with a new one. 6. Measure the clearance between the spacer collar and 5th gear. 7. If the clearance exceeds the service limit, measure distance (B) on the spacer collar. 8. If distance (A) is less than service limit, replace the spacer collar with a new one. If distance (B) is within the service limit, measure thickness of 5th gear. If the thickness of 5th gear is less than the service limit, replace 5th gear with a new one. If the thickness of 5th gear is within the service limit, replace the 5th synchro hub with a new one. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Mainshaft, M/T > Component Information > Testing and Inspection > Page 6350 Mainshaft: Adjustments 1. Remove the thrust shim and oil guide plate from the transmission housing. 2. Install the 3rd/4th synchro hub, spacer collar, 5th synchro hub, ball bearing, and thrust washer on the mainshaft. Install the assembly in the transmission 3. Measure the distance (B) between the end of the transmission housing and thrust washer. NOTE: - Use a straight edge and feeler gauge. - Measure at three locations and average the readings. 4. Measure the distance (C) between the surfaces of the clutch housing and bearing inner race. NOTE: Use a straight edge and feeler gauge. - Measure at three locations and average the readings Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Mainshaft, M/T > Component Information > Testing and Inspection > Page 6351 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Mainshaft, M/T > Component Information > Testing and Inspection > Page 6352 5. Select the proper thrust shim on the basis of the following calculations: NOTE: Do not use more than two thrust shims. (Basic Formula) (B) + (C) - 0.95 = thrust shim thickness Example of calculation: Distance (B)(2.00 mm) + Distance (C)(0.09 mm) = 2.09 mm subtract the spring washer height (0.95 mm) = the required thrust shim (1.14 mm) 6. Install the oil guide plate and thrust shim selected in the transmission housing. NOTE: Clean the thrust washer, spring washer and thrust shim thoroughly before installation. - Install the thrust washer, spring washer and thrust shim properly. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Mainshaft, M/T > Component Information > Testing and Inspection > Page 6353 7. Install the thrust washer and spring washer in the 8. Install the mainshaft in the clutch housing. 9. Place the transmission housing over the mainshaft and onto the clutch housing. 10. Tighten the clutch and transmission housings with several 8 mm bolts. 11. Tap the mainshaft with a plastic hammer. 12. Check the thrust clearance in the manner described below. NOTE: Measurement should be made at room temperature. a. Slide the mainshaft base and the collar over the mainshaft. b. Attach the mainshaft holder to the mainshaft as follows: - Back-out the mainshaft holder bolt and loosen the two hex bolts. - Fit the holder over the mainshaft so its lip is towards the transmission. - Align the mainshaft holder's lip around the groove at the inside of the mainshaft splines, then tighten the hex bolts. c. Seat the mainshaft fully by tapping its end with a plastic hammer. d. Thread the mainshaft holder bolt in until it just contacts the wide surface of the mainshaft base. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Mainshaft, M/T > Component Information > Testing and Inspection > Page 6354 e. Zero a dial gauge on the end of the mainshaft. f. Turn the mainshaft holder bolt clockwise; stop turning when the dial gauge has reached its maximum movement. The reading on the dial gauge is the amount of mainshaft end play. CAUTION: Turning the mainshaft holder bolt more than 60 degrees after the needle of the dial gauge stops moving may damage the transmission. g. If the reading is within the standard, the clearance is correct. If the reading is not within the standard, recheck the thrust shim thickness. Standard: 0.11-0.18 mm (0.004-0.007 in) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Mainshaft, M/T > Component Information > Service and Repair > Index Mainshaft: Service and Repair Index NOTE: The 3rd/4th and 5th synchro hubs are installed with a press. Prior to reassembling, clean all the parts in solvent, dry them and apply lubricant to any contact surfaces. The 3rd/4th and 5th synchro hubs, however, should be installed with a press before lubricating them. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Mainshaft, M/T > Component Information > Service and Repair > Index > Page 6357 Mainshaft: Service and Repair Disassembly 1. Remove the ball bearing using a bearing puller as shown. CAUTION: Remove the synchro hubs using a press and steel blocks as shown. Use of a jaw-type puller can cause damage to the gear teeth. 2. Support 4th gear on steel blocks as shown and press the mainshaft out of the 5th synchro hub. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Mainshaft, M/T > Component Information > Service and Repair > Index > Page 6358 3. Support the 3rd gear on steel blocks as shown and press the mainshaft out of the 3rd/4th synchro hub. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Mainshaft, M/T > Component Information > Service and Repair > Index > Page 6359 Mainshaft: Service and Repair Reassembly NOTE: When installing the 3rd/4th and 5th synchro hubs, support the shaft on the steel blocks and install synchro hubs using a press. 1. Support 2nd gear on steel blocks as shown, then install the 3rd/4th synchro hub using the special tools and a press as shown. 2. Install the 3rd/4th synchro sleeve by align the stoppers of the 3rd/4th synchro sleeve and hub. NOTE: After installing, inspect the operation of the 3rd/4th synchro hub set. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Mainshaft, M/T > Component Information > Service and Repair > Index > Page 6360 3. Install the 5th synchro hub using the special tools and a press as shown. 4. Install the ball bearing using the special tools and a press as shown. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Reverse Idler Gear > Component Information > Service and Repair Reverse Idler Gear: Service and Repair 1. Remove the reverse shift holder. 2. Remove the reverse idler gear shaft and reverse idler gear. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Fork, M/T > Component Information > Testing and Inspection > Reverse Shift Fork Shift Fork: Testing and Inspection Reverse Shift Fork 1. Measure the clearance between the reverse shift fork and shift piece pin. Standard: 0.05-0.35 mm (0.002-0.014 in) Service Limit: 0.5 mm (0.02 in) 2. If the clearance exceeds the service limit, measure the width of the groove in the reverse shift fork. If the width of the groove exceeds the standard, replace the reverse shift holder with a new one. If the width of the groove is within the standard, replace the 5th/reverse shift piece with a new one. 3. Measure the clearance between the reverse idler gear and reverse shift fork. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Fork, M/T > Component Information > Testing and Inspection > Reverse Shift Fork > Page 6368 4. If the clearance exceeds the service limit, measure the width of the reverse shift fork. If the width exceeds the standard, replace the reverse shift holder with a new one. If the width is within the standard, replace the reverse idler gear with a new one. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Fork, M/T > Component Information > Testing and Inspection > Reverse Shift Fork > Page 6369 Shift Fork: Testing and Inspection Shift Fork Assembly 1. Measure the clearance between each shift fork and its matching synchro sleeve. 2. If the clearance exceeds the service limit, measure the thickness of the shift fork fingers. 3. If the thickness of the shift fork fingers is less than the standard, replace the shift fork with a new one. If the thickness of the shift fork fingers is within the standard, replace the synchro sleeve with a new one. NOTE: The synchro sleeve and synchro hub should be replaced as a set. 4. Measure the clearance between the 3rd/4th shift fork and shift arm B. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Fork, M/T > Component Information > Testing and Inspection > Reverse Shift Fork > Page 6370 5. If the clearance exceeds the service limit, measure the width of the shift arm B. 6. If the width of the shift arm B is less than the service limit, replace the shift arm B with a new one. If the width of the shift arm B is within the service limit, replace the 3rd/4th shift fork with a new one. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Fork, M/T > Component Information > Service and Repair > Mainshaft/Countershaft/Shift Fork Shift Fork: Service and Repair Mainshaft/Countershaft/Shift Fork 1. Remove the interlock guide bolt from under the clutch housing 2. Remove the shift arm B attaching bolt. 3. Remove the mainshaft and countershaft assemblies with the shift fork from the clutch housing. NOTE: Before removing the mainshaft and countershaft assemblies, tape the mainshaft spline to protect it. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Fork, M/T > Component Information > Service and Repair > Mainshaft/Countershaft/Shift Fork > Page 6373 Shift Fork: Service and Repair Shift Fork Assembly NOTE: - When disassembling, pay attention to the steel balls as the springs may force them out. - When assembling, install the shift fork shaft with its detents facing the hole where the balls are inserted. - The steel balls are all of the same size (5/16 in). Prior to reassembling, clean all the parts in solvent, dry them and apply lubricant to any contact parts. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Fork, M/T > Component Information > Service and Repair > Mainshaft/Countershaft/Shift Fork > Page 6374 Shift Fork: Service and Repair Shift Rod NOTE: The steel balls are all of the same size (5/16 in). 1. Remove the differential assembly. 2. Remove the 28 mm plug bolt and 1st/2nd select spring. 3. Remove the shift arm C attaching bolt. 4. Remove the shift arm shaft. NOTE: Be careful not to lose the steel ball. 5. Remove the steel ball, spring, and collar. 6. Remove shift arms C and B, and the interlock, then remove the reverse select spring and reverse select retainer. 7. Remove the shift arm A attaching bolt, the set ball spring bolt, spring, and steel ball. 8. Remove the shift rod, then remove the shift arm A. 9. Remove the reverse lock cam. 10. Remove the magnet. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair Shifter M/T: Service and Repair NOTE: Inspect rubber parts for wear and damage when disassembling, replace any worn or damaged parts. - Install the clip as shown. - Turn the boot so the hole is facing down. - Make sure the boot is installed on the shift rod. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Component Information > Service and Repair > Overhaul Shift Linkage: Service and Repair Overhaul NOTE: Inspect rubber parts for wear and damage when disassembling, replace any worn or damaged parts. - Install the clip as shown. - Turn the boot so the hole is facing down. - Make sure the boot is installed on the shift rod. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Component Information > Service and Repair > Overhaul > Page 6382 Shift Linkage: Service and Repair Back-Up Light Switch NOTE: Check the switch. 1. Disconnect the connector, then remove the back-up light switch connector from the connector clamp. 2. Remove the back-up light switch. 3. Install the new washer and back-up light switch. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Shift Interlock Control Module > Component Information > Locations Shift Interlock Control Module: Locations Behind Left Side Of Dash Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Locations Shift Interlock Switch: Locations Behind Left Side Of Dash Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > A/T Gear Position Signal <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Locations A/T Gear Position Signal: Locations Below Center Console Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > A/T Gear Position Signal <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Locations > Page 6396 A/T Gear Position Signal: Description and Operation PURPOSE This signals the Engine Control Module (ECM) when the Transmission is in Neutral or Park position. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > A/T Gear Position Signal <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Locations > Page 6397 A/T Gear Position Signal: Testing and Inspection Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > A/T Gear Position Signal <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Locations > Page 6398 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations Shift Interlock Solenoid: Locations Below Center Console Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 6405 Shift Interlock Solenoid: Testing and Inspection 1. Remove instrument panel lower cover and knee bolster. 2. Remove steering column upper and lower covers. 3. Disconnect shift lock solenoid 2-P connector. Fig. 13 Shift Lock Solenoid Test Terminal 4. Connect battery power momentarily to No. 1 terminal of shift lock solenoid, Fig. 13, noting the following: a. Ensure power is not applied to terminal No. 2, as the solenoid will be shorted out. b. Ensure shift lock stop does not protrude when in On position. c. Ensure shift lock stop does protrude more than 0.30 inches when Off. 5. Check that shift lock releases when release lever is pushed. 6. Check that shift lock solenoid locks when lever is released. 7. If solenoid does not work as outlined, replace. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 6406 Shift Interlock Solenoid: Service and Repair 1. Remove instrument panel lower cover and knee bolster. 2. Remove steering column upper and lower covers. 3. Disconnect 2-P electrical connector from shift lock solenoid. 4. Remove shift lock extension. Fig. 16 Shift Lock Solenoid Replacement 5. Remove screw and detent spring washer, Fig. 16. 6. Remove shift lock solenoid. 7. Reverse procedure to install, noting the following: a. Ensure shift lock stop does not protrude when solenoid is On. b. Ensure shift lock solenoid does protrude more than 0.30 inches when shift lock is Off. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications Resistance ........................................................................................................................................... ............................... 14.1 - 15.5 Ohms at 25°C (77°F) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 6410 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 6411 Torque Converter Clutch Solenoid: Testing and Inspection NOTE: Lock-up control solenoid valves A and B must be removed/replaced as an assembly. 1. Disconnect the connector from the lock-up control solenoid valve A/B. 2. Measure the resistance between the No. 1 terminal (solenoid valve A) of the lock-up control solenoid valve connector and body ground, and between the No. 2 terminal (solenoid valve B) and body ground. Standard: 14.1 - 15.5 Ohms at 25°C (77°F) 3. Replace the lock-up control solenoid valve assembly if the resistance is out of specification. 4. Connect the No. 1 terminal of the lock-up control solenoid valve connector to the battery positive terminal and body ground. A clicking sound should be heard. Connect the No. 2 terminal to the battery positive terminal and body ground. A clicking sound should be heard. 5. If there is no clicking, check for continuity between the engine control module (ECM) A19 or A17 harness and body ground using the Test Harness: O7LAJ - PT3O1OA. NOTE: Always use the Test Harness (O7LAJ PT3O1OA) for checking. 6. Replace the lock-up control solenoid valve assembly if there is continuity between the ECM A19 or A17 harness and body ground. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 6412 Torque Converter Clutch Solenoid: Service and Repair 1. Remove the mounting bolts and lock-up control solenoid valve assembly. NOTE: Be sure to remove or replace the lock-up control solenoid valves A and B as an assembly. 2. Check the lock-up control solenoid valve oil passages for dust or dirt, and replace as an assembly, if necessary. 3. Clean the mounting surface and oil passages of the lock-up control solenoid valve assembly and install a new filter/gasket. 4. Check the connector for rust, dirt or oil and reconnect it securely. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Shift Interlock Control Module > Component Information > Locations Shift Interlock Control Module: Locations Behind Left Side Of Dash Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Locations Shift Interlock Switch: Locations Behind Left Side Of Dash Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > A/T Gear Position Signal <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Locations A/T Gear Position Signal: Locations Below Center Console Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > A/T Gear Position Signal <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Locations > Page 6426 A/T Gear Position Signal: Description and Operation PURPOSE This signals the Engine Control Module (ECM) when the Transmission is in Neutral or Park position. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > A/T Gear Position Signal <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Locations > Page 6427 A/T Gear Position Signal: Testing and Inspection Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > A/T Gear Position Signal <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Locations > Page 6428 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Description and Operation ABS Light: Description and Operation ABS Indicator Light: The ABS indicator light comes on for three seconds and then goes off when the control unit detects no problem during the initial diagnosis right after the engine starts. However, the ABS indicator light can stay on for up to 40 seconds when the control unit starts to check for pump overrun, etc. during the initial diagnosis. The ABS indicator light comes on, and the ABS control unit memorizes the diagnostic trouble code (DTC) under certain conditions. - The parking brake is applied for more than 30 seconds while the vehicle is being driven. (DTC 2-1) - The transmission downshifted excessively. (DTC 4-1, 4-2) - The vehicle loses traction, and the front wheels spin for more than one minute when starting from a stuck condition in mud, snow, or sandy road. (DTC 4-8) - The tires adhesion is lost due to excessive cornering speed. (DTC 5, 5-4, 5-8) - The vehicle is driven on an extremely rough road. (DTC 8-1) - The vehicle is interfered by strong radio waves (noise), for example, illegal radio, etc. (DTC 8-2) NOTE: If there is any trouble in the system, the ABS indicator light turns on during driving. Diagnostic Trouble Code (DTC): - When the control unit detects a problem and the ABS indicator light comes on, the control unit memorizes the DTC. - The control unit has three memory registers. When a problem occurs, the control unit stores the DTC in the first memory register. If another problem occurs, or the same problem occurs again, the control unit moves the first DTC to the next memory register, and stores the second DTC in the first register. If there's a third problem occurrence, the two existing DTCs are moved up one register, and the third DTC is stored in the first register. If problems continue to occur, the oldest problem is moved out of the last register and lost, and the most recent problem is stored in the first register. When the same problem occurs three times, the same DTC is stored in all memory registers. (Refer to the Symptom-to- System Chart for diagnostic period.) - The most recent DTC is indicated first, and the oldest DTC is indicated last. - The DTCs are erased from the control unit when the ABS control unit +B2 power supply or connector is disconnected. - The control unit's memory can be erased by disconnecting the ABS B2 fuse for more than three seconds. Self-diagnosis: - There are three self-diagnoses described below. 1. Initial diagnosis: Performed right after the engine starts until the ABS indicator light goes off. 2 Regular diagnosis: Continuously performed (under some conditions) after the ABS indicator light goes off until the engine stops. 3. Individual part/system diagnosis: Diagnosis about a specific part/system under its operating conditions. - The CPU (central processing unit) controls the following when it detects a problem during self-diagnosis: 1. Turns the ABS indicator light ON. 2. Turns the front and rear fail-safe relays off. 3. Stops the ABS control. 4. Stops the ABS pump. (The pump may work under some conditions.) 5. After the DTC is stored in the control unit, the CPU stops self-diagnosis. Kickback and Pump Operation: - When the engine is started, the ABS control unit begins the initial diagnosis and operates the solenoid valve one time. The kickback may be felt when the brake pedal is depressed. - When the ABS control unit detects the pressure switch OFF signal during the initial diagnosis, it operates the pump motor, and performs the pump motor over-run diagnosis and pump motor diagnosis. Therefore, there are two cases where the pump motor operates or does not operate after the engine is started. - Normally, after the initial diagnosis, the pump motor operates based on the pressure switch signal, regardless of the vehicle speed. Troubleshooting: - When two or three DTCs are stored in the control unit, perform troubleshooting for the DTC that appears first. - When a customer's reported problem cannot be verified on the car, ask the customer about the conditions when the ABS indicator light came ON, and test drive the car under those conditions, if possible. When the ABS indicator light does not come ON during the test, check for loose terminals and check by shaking the harnesses and connectors while following the flowchart. - The connector terminal numbers are viewed from the wire side for the female terminals, and from the terminal side for the male terminals. - After the repair finished off, test drive the car and check the ABS indicator light does not come ON again during the test. (Refer to the Symptom-to-System Chart for diagnostic period.) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Description and Operation > Page 6434 ABS Light: Service and Repair ABS LAMP RESET PROCEDURE ^ If all repairs have been completed, disconnect the ABS B2 (15 A) fuse in the under-hood fuse/relay box for at least three (3) seconds to erase the ABS control unit's memory. NOTE: The ABS control unit's memory will be erased if the connector is disconnected from the ABS control unit or the ABS control unit is removed from the body. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Main Relay > Component Information > Locations ABS Main Relay: Locations Fuse/Relay Information-Under-hood ABS Fuse/Relay Box Right Side Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Brake Fluid Accumulator > Component Information > Description and Operation Brake Fluid Accumulator: Description and Operation The accumulator is a pneumatic type which accumulates high pressure brake fluid fed from the pump incorporated in the power unit. When the anti-lock brake system operates, the accumulator feeds high pressure brake fluid to the modulator valve via the inlet side of the solenoid valve. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Brake Fluid Accumulator > Component Information > Service and Repair > Removal and Installation Brake Fluid Accumulator: Service and Repair Removal and Installation Fig. 95 Accumulator Replacement Refer to Fig. 95 when replacing accumulator. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Brake Fluid Accumulator > Component Information > Service and Repair > Removal and Installation > Page 6443 Brake Fluid Accumulator: Service and Repair Disposal WARNING: The accumulator contains high pressure nitrogen gas. Do not puncture, expose to flame or attempt to disassemble the accumulator or it may explode. Fig. 79 Relieving Nitrogen Gas From Accumulator For Disposal 1. Secure accumulator in a vise with relief plug pointing straight up, Fig. 84. 2. Slowly turn plug 3 1/2 turns and wait three minutes for all pressure to escape. 3. Remove plug completely and dispose of accumulator unit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Motor <--> [Brake Fluid Pump] > Component Information > Locations ABS Motor: Locations Right Rear Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Brake Fluid Pump Relay > Component Information > Locations Brake Fluid Pump Relay: Locations Fuse/Relay Information-Under-hood ABS Fuse/Relay Box Right Side Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic Connector - ABS > Component Information > Locations Diagnostic Connector - ABS: Locations Below Right Front Seat Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations Electronic Brake Control Module: Locations Right Side Of Trunk Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 6456 Electronic Brake Control Module: Description and Operation The main function section of the control unit performs calculations on the basis of the signals from each speed sensor. It controls the operation of the anti-lock brake system by putting the solenoid valves in the modulator unit into action for each front brake and for the two rear brakes. The sub-function section gives driving signals to the pump motor and also gives self-diagnosis signals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 6457 Electronic Brake Control Module: Service and Repair Fig. 90 Control Unit Replacement Refer to Fig. 90 when replacing the control unit. 1. Remove right side trunk trim panel. 2. Disconnect control unit connectors. 3. Remove control unit mounting bolts, then the control unit. When control unit mounting bolts are removed, the control unit's memory is cleared. 4. Reverse procedure to install. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Fail Safe Relay, ABS / Traction Control > Component Information > Locations > Front Fail Safe Relay: Locations Front Right Side Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Fail Safe Relay, ABS / Traction Control > Component Information > Locations > Front > Page 6462 Fail Safe Relay: Locations Rear Right Side Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Power Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Locations Power Unit: Locations Right Rear Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Power Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Description and Operation > Brake Pressure Modulator Valve Power Unit: Description and Operation Brake Pressure Modulator Valve Modulators and solenoid valves are integrated in the modulator unit. The modulators for front and rear brakes are of independent construction and are positioned vertically. The modulators for rear brakes are provided with a proportioning control valve to prevent the rear wheels from locking when the anti-lock brake system is malfunctioning or not activated. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Power Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Description and Operation > Brake Pressure Modulator Valve > Page 6468 Power Unit: Description and Operation Power Unit The power unit consists of a motor and a plunger pump. Since an eccentric bearing is positioned on the end of the motor shaft, the rotation of the motor provides the reciprocating motion of the plunger. The brake fluid is thus pressurized and fed to the accumulator. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Power Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Service and Repair > Brake Pressure Modulator Valve Power Unit: Service and Repair Brake Pressure Modulator Valve CAUTION: Do not spill brake fluid on the car; it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Power Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Service and Repair > Brake Pressure Modulator Valve > Page 6471 Relieving Accumulator/Line Pressure WARNING: Use the Bleeder T-wrench before disassembling the parts shaded in the illustration. 1. Open the hood. 2. Remove the red cap from the bleeder on the modulator body. 3. Install the special tool on the maintenance bleeder and turn it out slowly 90°to collect high-pressure fluid into the reservoir. Turn the special tool out one complete turn to drain the brake fluid thoroughly. 4. Retighten the maintenance bleeder and discard the fluid. 5. Reinstall the red cap. Reservoir Brake Fluid Draining 1. Draining brake fluid from modulator tank: The brake fluid may be sucked out through the top of the modulator tank with a syringe. It may also be drained through the pump joint after disconnecting the pump hose. 2. Draining brake fluid from master cylinder: Loosen the bleed screw and pump the brake pedal to drain the brake fluid from the master cylinder. WARNING: High-pressure fluid will squirt out if the shaded hose and pipe are removed. - To drain high-pressure brake fluid, follow the procedure for releaving accumulator line pressure. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Power Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Service and Repair > Brake Pressure Modulator Valve > Page 6472 Modulator/Pump Removal/Installation CAUTION: - Be careful not to bend or damage the brake pipes when removing the modulator unit. - Do not spill brake fluid on the car; it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water. - To prevent spills, cover the hose joints with rags or shop towels. - Before reassembling, check that all parts are free of dust and other foreign particles. - Do not mix different brands of brake fluid as they may not be compatible. - Do not reuse the drained fluid. Use only clean DOT 3 or 4 brake fluid. - When connecting the brake pipes, make sure that there is no interference between the brake pipes and other parts. 1. Remove the battery and battery tray. 2. Disconnect the solenoid, motor and pressure switch connectors. 3. Disconnect the brake pipes from the modulator unit. 4. Remove the mounting bolts and nut, then remove the modulator/ABS pump assembly from the frame. 5. Install the modulator/ABS pump assembly in the reverse order of removal. 6. After installation, bleed the air from the system. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Power Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Service and Repair > Brake Pressure Modulator Valve > Page 6473 Modulator/Pump Index/Torque Before removing the modulator-to-pump high-pressure line, be sure to relieve the pressure fluid from the maintenance bleeder. Refer to Relieving Accumulator/Line Pressure above. CAUTION: - Do not spill brake fluid on the car; it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water. - To prevent spills, cover the hose joints with rags or shop towels. - Before reassembling, check that all parts are free of dust and other foreign particles. - Do net mix different brands of brake fluid as they may not be compatible. - Do not reuse the drained fluid. Use only clean DOT 3 or 4 brake fluid. - Do not try to disassemble the modulator unit and pump assembly. Replace the modulator unit as an assembly if it is defective. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Power Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Service and Repair > Brake Pressure Modulator Valve > Page 6474 Solenoids Leak Test NOTE: If a solenoid leaks excessively, the brake fluid level in the modulator reservoir tank will rise when operating the ABS motor. The modulator reservoir may also overflow. 1. Connect an ohmmeter between the YEL and YEL terminals of the pressure switch connector. 2. Attach the positive (+) lead of a fully charged 12 V battery to the RED/WHT terminal of the motor connector and negative (-) lead to the GRN terminal, and install a switch between negative lead and GRN terminal as shown. 3. Turn the switch on to allow sufficient pressure to build up within the accumulator and check for continuity. If the ohmmeter shows continuity (pressure switch turned on), run the motor for 10 seconds more, then turn the switch off. Check if the solenoid hisses or squeaks. Replace the modulator unit if the solenoid hisses or squeaks. - Check the pressure switch for continuity within 30 minutes. It is normal if there is continuity. If there is no continuity, a solenoid is faulty or there is a high-pressure line leak. Accumulator Replacement - Before removing the modulator-to-accumulator high pressure line, be sure to relieve the pressure fluid from the maintenance bleeder. Refer to Relieving Accumulator/Line Pressure above. 1. Loosen the flare nuts and remove the accumulator pipe 2. Remove the three mounting bolts and the accumulator from the modulator unit. 3. Install a new accumulator in the reverse order of removal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Power Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Service and Repair > Brake Pressure Modulator Valve > Page 6475 4. Bleed the air from the high-pressure line. Refer to Air Bleeding with ALB Checker below. Disposal The accumulator contains high pressure nitrogen gas. Do not puncture, expose to the flame, or attempt to disassemble the accumulator or it may explode and severe personal injury may result. 1. Secure the accumulator in a vise so that the relief plug points straight up. 2. Slowly turn the plug three and a half turns and then wait three minutes for all pressure to escape. 3. Remove the plug completely and dispose of the accumulator. Bleeding Air Bleeding with ALB Checker CAUTION: - Do not spill brake fluid on the car; it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water. - Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid. - Do not mix different brands of brake fluid as they may not be compatible. - Do not reuse the drained fluid. Use only clean DOT 3 or 4 brake fluid. 1. Place the vehicle on level ground with the wheels blocked. Put the transmission in neutral for manual transmission models, and in (P) position for automatic transmission models. Release the parking brake. 2. Disconnect the ABS inspection connector (6P) from the cross-member under the passenger's seat and connect the ABS inspection connector (6P) to the ALB checker. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Power Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Service and Repair > Brake Pressure Modulator Valve > Page 6476 3. Fill the modulator reservoir to the MAX level line and install the reservoir cap. 4. Start the engine and allow it to idle for a few minutes, then stop it. Check the fluid level in the modulator reservoir and refill to the MAX level line if necessary. 5. Bleed high-pressure fluid from the maintenance bleeder with the special tool. 6. Refill the modulator reservoir to the MAX level line and install the reservoir cap. 7. Turn the Mode Selector switch of the checker to 2. 8. While depressing the brake pedal firmly, push the Start Test switch to operate the modulator. There should be kickback on the brake pedal. If not, repeat steps 5 to 8. NOTE: Continue to depress the brake pedal firmly when operating the checker. 9. Turn the Mode Selector to 3, 4, and 5. Perform step 8 for each of the test mode positions. 10. Refill the modulator reservoir to the MAX level line and install the reservoir cap. WARNING: Disconnect the ALB check before driving the car. A collision can result from a reduction, or complete loss of braking ability causing severe personal injury or death. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Power Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Service and Repair > Brake Pressure Modulator Valve > Page 6477 Power Unit: Service and Repair Power Unit Fig. 104 Power Unit Replacement Refer to Fig. 104 when replacing power unit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Front Wheel Speed Sensor: Locations Front Behind Left Front Wheel (Right Similar) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Front > Page 6482 Wheel Speed Sensor: Locations Rear Behind Left Rear Wheel (Right Similar) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Page 6483 Wheel Speed Sensor: Description and Operation WHEEL SPEED SENSOR The speed sensor is a non-contact type which detects the rotating speeds of the wheel. It is composed of a permanent magnet and coil. When the gear pulsers at each wheel turn, the magnetic coil in the speed sensor alternates, generating voltages with frequency in proportion to wheel rotating speed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Testing and Inspection > Toothed Ring Wheel Speed Sensor: Testing and Inspection Toothed Ring INSPECTION OF THE TOOTHED RING 1. Check the front and rear pulser for chipped or damaged teeth. 2. Measure the air gap between the wheel sensor and pulser all the way around while rotating the pulser. Standard: 0.4 - 1.0 mm (0.02 - 0.04 inch) NOTE: If the gap exceeds 1.0 mm (0.04 inch), the probability is a distorted suspension arm which should be replaced. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Testing and Inspection > Toothed Ring > Page 6486 Wheel Speed Sensor: Testing and Inspection Wheel Speed Sensor TESTING THE WHEEL SPEED SENSOR 1. Check pulser for chipped or damaged teeth and replace as necessary. Fig. 82 Measureing Front Speed Sensor Air Gap 2. Measure air gap between sensor and pulser all the way around while rotating driveshaft by hand, Fig. 82. If gap exceeds its maximum specification at any point, the knuckle is most likely distorted and should be replaced. Air gap should be 0.016-0.039 inches. WHEEL SENSOR SIGNAL CONFIRMATION 1. With ignition switch off, disconnect 6-P inspection connector from connector cover on crossmember under passenger seat and connect it to anti-lock brake checker tool Nos. 07HAJ-SG0010A or 07HAJ-SG0010B, or equivalents. 2. Raise and support vehicle so all four wheels are off ground. 3. Turn ignition switch to on position, then turn mode selector switch on anti-lock brake checker to 0. 4. With transaxle in Neutral position, rotate each wheel at least one revolution per second and confirm that its respective monitor light on the checker blinks as wheel is rotating. Rotating wheel too slowly will produce only weak blinks of monitor lights. Perform tests in shaded area, as monitor lights may be difficult to see in bright sunlight. If the front wheels won't spin fast enough to get monitor indication, start engine and slowly accelerate and decelerate front wheels. 5. If any monitor light fails to blink, check the suspected sensor, its air gap, wiring and connectors. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor: Service and Repair Front Fig. 108 Front Speed Sensor Replacement Refer to Fig. 108 when replacing front speed sensor. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 6489 Wheel Speed Sensor: Service and Repair Rear Fig. 113 Rear Speed Sensor Replacement Refer to Fig. 113 when replacing rear speed sensor. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > System Bleeding Brake Bleeding: Service and Repair System Bleeding Anti-Lock Brake System Anti-Lock Brake Bleeding See: With Anti-Lock Brakes (Using ALB Checker) With Anti-Lock Brakes (Using ALB Checker) Park vehicle on level ground with wheels blocked. When bleeding brakes, put manual transaxle in the Neutral position and automatic transaxle in the Park position. 1. With ignition switch Off, disconnect 6-P inspection connector from connector cover on the crossmember under passenger seat and connect it to anti-lock brake checker tool Nos. 07HAJ-SG0010A or 07HAJ-SG0010B, or equivalents. 2. Fill modulator reservoir to MAX level and install reservoir cap. 3. Start engine and allow it to idle for a few minutes, then shut engine off. Check fluid in modulator reservoir and refill to MAX level if necessary. Fig. 86 Bleeding High Pressure Fluid At Maintenance Bleeder 4. Bleed high pressure fluid from maintenance bleeder with bleeder wrench tool No. 07HAA-SG00101, or equivalent, Fig. 86. 5. Refill modulator reservoir to MAX level and install reservoir cap. 6. Turn mode selector switch on checker to 2. 7. While depressing brake pedal firmly, push start test switch to operate modulator. There should be kickback on brake pedal. If there is no kickback, repeat bleeding sequence as outlined above. 8. Turn mode selector switch on checker to 3, 4 and 5. At each test mode position, refill modulator reservoir to MAX level and install reservoir cap. 9. Refill modulator reservoir to MAX level and install reservoir cap. Disconnect ALB checker before driving car. A collision can result from a reduction, or complete loss of braking ability. Without Anti-Lock Brakes CAUTION: - Always use Genuine Honda DOT 3 Brake Fluid. Using a non-Honda brake fluid can cause corrosion and decrease the life of the system. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > System Bleeding > Page 6494 - Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid. - Do not spill brake fluid on the vehicle, it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water. NOTE: The reservoir on the master cylinder must be at the MAX (upper) level mark at the start of the bleeding procedure and checked after bleeding each brake caliper. Add fluid as required. 1. Make sure the brake fluid level in the reservoir is at the MAX (upper) level line. 2. Have someone slowly pump the brake pedal several times, then apply steady pressure. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > System Bleeding > Page 6495 3. Loosen the brake bleed screw to allow air to escape from the system. Then tighten the bleed screw securely. Brake Bleeding Sequence 4. Repeat the procedure for each wheel in the sequence shown until air bubbles no longer appear in the fluid. 5. Refill the master cylinder reservoir to the MAX (upper) level line. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > System Bleeding > Page 6496 Brake Bleeding: Service and Repair ABS Hydraulic Component Bleeding and Fluid Service Relieving Accumulator/Line Pressure WARNING: Use the Bleeder T-wrench before disassembling the parts shaded in the illustration Collecting High-pressure Fluid Into Reservoir Through Maintenance Bleeder - Open the hood. - Remove the red cap from the bleeder on the modulator body. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > System Bleeding > Page 6497 Fig. 81 Brake System Pressure Relief - Install the special tool on the maintenance bleeder, and turn it out slowly 90° to collect high-pressure fluid into the reservoir. Turn the special tool out one complete turn to drain the brake fluid thoroughly. - Retighten the maintenance bleeder, and discard the fluid. - Reinstall the red cap. Brake Fluid Change Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > System Bleeding > Page 6498 Fig. 85 Draining Brake Fluid Reservoir W/Syringe 1. Brake fluid may be sucked out through the top of modulator reservoir with a syringe. It may also be drained through the pump joint after disconnecting pump hose, Fig. 85. 2. Loosen master cylinder bleed screw and pump brake pedal to drain brake fluid from master cylinder. WARNING: - High-pressure fluid will squirt out if the shaded hose and pipe are removed. - To drain high-pressure brake fluid. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Banjo Bolt 25 ft.lb Front Caliper Bleed Screw 6 ft.lb Front Caliper Bolt (Bottom) 20 ft.lb Front Caliper Bolt (Top) 25 ft.lb Front Caliper Bracket Bolt 80 ft.lb Parking Brake Nut 20 ft.lb Rear Caliper Bleed Screw 7 ft.lb Rear Caliper Bracket Bolt 28 ft.lb Rear Caliper Mounting Bolt 17 ft.lb Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front Brake Caliper: Service and Repair Front Removal Ensure dirt or other foreign matter is not allowed to contaminate brake fluid. Do not mix different types of brake fluid, as they might not be compatible. Fig. 2 Front Pin Siding Disc Brake Caliper 1. Refer to Fig. 2 when replacing calipers. 2. Raise and support front of vehicle, then remove wheel and tire assemblies. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 6505 Fig. 19 Brake Line Banjo Bolt 3. Remove banjo bolt and disconnect brake hose from caliper, Fig. 11. 4. Remove caliper bolts, then the caliper. Installation 1. Install caliper and caliper bolts. 2. Connect brake hose to caliper, then install banjo bolt. 2. Bleed front brakes, then install wheel and tire assemblies. Disassembly Ensure dirt or other foreign matter is not allowed to contaminate brake fluid. Do not mix different types of brake fluid, as they might not be compatible. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 6506 Fig. 2 Front Pin Siding Disc Brake Caliper 1. Refer to Fig. 2 when overhauling calipers. 2. Remove caliper assembly from vehicle. Fig. 12 Pad Spring 3. Remove pad spring from caliper body, if equipped, Fig. 12. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 6507 Fig. 19 Brake Line Banjo Bolt 4. Place wooden block or shop rag in caliper opposite piston, then carefully remove piston from caliper by applying air pressure through brake line hole with OSHA-approved 30 psi nozzle, Fig. 11. 5. Remove boot clip, if equipped, then the piston boot and piston seal. Assembly Ensure dirt or other foreign matter is not allowed to contaminate brake fluid. Do not mix different types of brake fluid, as they might not be compatible. 1. Clean piston and caliper bore with brake fluid, then inspect for wear or damage. 2. Apply brake cylinder grease to new piston seal and install seal in cylinder groove. 3. Install piston boot, then the boot retaining clip. 4. Lubricate caliper cylinder and piston with brake fluid, then install piston in cylinder with dished end facing in. 5. Install pad spring in caliper housing. 6. Install caliper assembly. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 6508 Brake Caliper: Service and Repair Rear Disassembly - WARNING: Never use an air hose or dry brush to clean brake assemblies. - Use an OSHA-approved vacuum cleaner to avoid breathing brake dust. - Contaminated brake discs or pads reduce stopping ability. CAUTION: - Do not spill brake fluid on the car; it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water. - To prevent spills, cover the hose joints with rags or shop towels. - Clean all parts in brake fluid and air dry; blow out all passages with compressed air. 1. Remove the caliper shield. 2. Remove the lock pin and clevis pin. Remove the cable clip and disconnect the cable from the parking brake arm. 3. Remove the banjo bolt and two sealing washers. 4. Remove the two caliper mounting bolts and caliper body from the bracket. 5. Remove the pad spring from the caliper body. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 6509 6. Remove the piston by rotating the piston counterclockwise with the special tool and remove the piston boot. CAUTION: Avoid damaging the piston. 7. Remove the piston seal. CAUTION: Take care not to damage the cylinder bore. 8. Install the special tool between the caliper body and spring cover. CAUTION: Be careful not to damage the inside of the caliper cylinder during caliper disassembly. 9. Position the locknuts as shown, then turn the shaft until the plate just contacts the caliper body. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 6510 NOTE: Do not compress the spring under the spring cover. 10. Turn the shaft clockwise 1/4-1/2 turn to compress the adjusting spring B in the caliper body. CAUTION: To prevent damage to the inner components, do not turn the shaft more than 1/2 turn. 10. Turn the shaft clockwise 1/4-1/2 turn to compress the adjusting spring B in the caliper body. CAUTION: To prevent damage to the inner components, do not turn the shaft more than 1/2 turn. 11. Lower the locknuts fully and tighten the locknuts securely. NOTE: Keep the locknuts in this position until you reinstall the circlip. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 6511 12. Remove the circlip with snap ring pliers. 13. Hold the plate with your fingers and turn the shaft counterclockwise. Remove the special tool from the caliper. 14. Remove the adjusting bolt. 15. Remove the spring cover, adjusting spring B, spacer, bearing A and cup from the adjusting bolt. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 6512 16. Remove the sleeve piston, and remove the pin from the cam. 17. Remove the return spring. 18. Remove the parking lever and cam as an assembly from the caliper body. CAUTION: Do not loosen the parking nut with the cam installed in the caliper body. If the lever and shalt must be separated, hold the lever in a vise and loosen the parking nut. 19. Remove the cam boot. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 6513 Reassembly WARNING: - Never use an air hose or dry brush to clean brake assemblies. - Use an OSHA-approved vacuum cleaner to avoid breathing brake dust. - Contaminated brake discs or pads reduce stopping ability. - When reusing the pads, install them in their original positions to prevent loss of braking efficiency. CAUTION: - Do not spill brake fluid on the car; it may damage the paint: if brake fluid does contact the paint, wash it off immediately with water. - To prevent spills, cover the hose joints with rags or shop towels. - Clean all parts in brake fluid and air dry; blow out all passage with compressed air. - Before reassembling, check that all parts are free of dust and other foreign particles. - Replace parts with new ones whenever specified to do so. - Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid. - Do not mix different brands of brake fluid as they may not be compatible. - Do not reuse the drained fluid. Use only clean DOT 3 or 4 brake fluid. NOTE: - Coat piston, piston seal, and caliper bore with clean brake fluid. - Replace all rubber parts with new ones whenever disassembled. 1. Pack all cavities of the needle bearing with recommended grease. . Coat the new cam boot with recommended grease and install it in the caliper body. 3. Apply recommended grease to the pin contacting area of the cam and install the cam and lever assembly into the caliper body. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 6514 4. Install the return spring. CAUTION: - When the cam and lever were separated, be sure to assemble them before installing the cam in the caliper body. Install the lever and spring washer apply locking agent to the threads, and tighten the parking nut while holding the lever with a vise. - Avoid damaging the cam boot since it must be installed before the cam. - When installing the cam, do not allow the cam boot lips to turn outside in. 5. Install the pin in the cam. 6. Apply recommended grease to the new O-ring and install it on the sleeve piston. 7. Install the sleeve piston so the hole in the bottom of the piston is aligned with the pin in the cam and two pins on the piston are aligned with the holes in the caliper. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 6515 8. Coat a new cup with recommended grease, and install it with its groove facing the bearing A side of the adjusting bolt. 9. Fit the bearing A, spacer, adjusting spring B and spring cover on the adjusting bolt, and install them in the caliper cylinder. 10. Install the special tool on the spring cover and turn the shaft until the locknut contacts the plate 11. Check that the flared end of the spring cover is below the circlip groove. 12. Install the circlip in the groove, then remove the special tool. NOTE: Check that the circlip is seated in the groove properly. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 6516 13. Coat a new piston seal with silicone grease and in stall it in the caliper. 14. Apply brake cylinder grease (P/N: 08733-BO2OE) or equivalent rubber grease to the sealing lips and inside of a new piston boot, and install it in the caliper. 15. Coat the outside of the piston with brake fluid and install it on the adjusting bolt while rotating it clockwise with the special tool. 16. Install the pad spring on the caliper. 17. Install the brake pad retainers and brake pads. CAUTION: Avoid damaging the piston and piston boot. 18. Align the cutout in the piston with the tab on the inner pad. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 6517 19. Install the caliper on the caliper bracket and tighten the caliper mounting bolts. 20. Connect the brake hose to the caliper with new sealing washers and tighten the banjo bolt. 21. Insert the cable through the arm and connect the cable to the lever with the clevis pin and lock pin. Install the cable clip securely. 22. Fill the brake reservoir up and bleed the brake system. 23. Operate the brake pedal several times, then adjust the parking brake. 24. After installation, perform the following checks. - Check for leaks at hose and line joints or connections, and retighten if necessary. - Check the parking brake lever for operation and adjust if necessary. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair Brake Pad: Service and Repair WARNING: ^ Never use an air hose or dry brush to clean brake assemblies. ^ Use an OSHA-approved vacuum cleaner, to avoid breathing brake dust. 1. Block the front wheels, loosen the rear wheel lug. nuts slightly, support the rear of car on safety stands, then remove the rear wheels. Release the parking brake. Caliper Shield Removal 2. Remove the caliper shield. Caliper Removal 3. Remove the two caliper mounting bolts and the caliper from the bracket. CAUTION: ^ Thoroughly clean the outside of the caliper to prevent dust and dirt from entering inside. ^ Support the caliper with a piece of wire so that it does not hang from the brake hose. 4. Remove the pad shims, pads and pad retainers. 5. Using vernier calipers, measure the thickness of each brake pad lining. If lining thickness is less than service limit, replace the rear pads as a set. NOTE: Measurement does not include pad backing plate thickness. Brake Pad Thickness: Accord/Prelude Standard: 0.35 in (9.0 mm) Service Limit: 0.06 in (1.6 mm) Brake Pad Thickness: Civic/Del Sol Standard: 0.30 in (7.5 mm) Service Limit: 0.06 in (1.6 mm) 6. Clean the caliper thoroughly; remove any rust, and check for grooves or cracks. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Page 6521 Pad Retainer Installation 7. Make sure that the pad retainers are installed in the correct positions. Brake Pad And Shim Installation 8. Install the brake pads and pad shims on caliper bracket. ^ When reusing the pads, always reinstall the brake pads in their original positions to prevent loss of braking efficiency. ^ Contaminated brake discs or pads reduce stopping ability. Keep grease off the discs and pads. NOTE: ^ Apply Molykote M77 to the pad side of the shims. Wipe excess grease off the shims. ^ Install the inner pad with its wear indicator facing upward. 9. Rotate the caliper piston clockwise into place in the cylinder, then align the cutout in the piston with the tab on the inner pad by turning the piston back. CAUTION: Lubricate the boot with silicone grease to avoid twisting the piston boot. It piston boot is twisted, back it out so it sits properly. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Page 6522 Caliper Installation 10. Install the caliper on the caliper bracket and tighten the caliper mounting bolts. Caliper Shield Installation 11. Install the caliper shield. 12. Depress the brake pedal several times to make sure the brakes work, then road-test. NOTE: Engagement of the brake may require a greater pedal stroke immediately after the brake pads have been replaced as a set. Several applications of the brake pedal will restore the normal pedal stroke. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes - Brake Disc Refinishing Information Brake Rotor/Disc: Technical Service Bulletins Brakes - Brake Disc Refinishing Information 00-088 July 14, 2010 Applies To: ALL Models Brake Disc Refinishing Guidelines (Supersedes 00-088, dated October 6, 2006, to revise the information marked with the black bars) *REVISION SUMMARY The requirement to refinish new brake discs was removed.* American Honda does not allow replacement of brake discs under warranty unless the brake disc is beyond its service limit for refinishing. If the brake disc is within its service limit, you must refinish it. Maximum refinishing limits may be found in the Conventional Brakes section of the appropriate service manual. *Refinish brake discs only when they are scored or out of specification for runout or parallelism. See the appropriate service manual for the specifications.* American Honda requires refinishing of the front brake discs with an on-car brake lathe that mounts to the steering knuckle. Use of an on-car, steering knuckle- mounted lathe is critical because it corrects runout of the hub and disc as an assembly. Experience has shown that very small amounts of runout, not felt as brake pulsation initially, will grow and become noticeable as the discs are subjected to heat and wear over time and mileage. Two on-car brake lathes are recommended. The Kwik-Lathe, model number KWY-108000501, is supported with automatic shipments of adapters for new models, when required. The Accu-turn On-car Brake Lathe, model ACCHONOCLPKG, is also recommended. A power driver is required for the 82000 and is highly recommended for all other models. The Kwik-Lathe power driver model number is KWY-108012005; the Accu-turn lathe includes a power driver. Here are some advantages of using power drivers: ^ The disc is rotated at the optimum speed for a smooth and consistent cut. ^ There is no need to climb in and out of the vehicle to start and stop the engine or to shift the transmission. ^ Securing the opposite wheel with a tie-down strap is not required. ^ There is no waiting for the engine to return to idle and no concern about engine speed changes that can adversely affect brake disc cut and finish. ^ The Traction Control System (TCS) is not involved. ^ Consistent cutting speed increases cutting tool life. ORDERING INFORMATION Order brake lathes and power drivers through the Honda Tool and Equipment Program. To place an order, call or use the fax order form provided in your Honda Tool and Equipment Program Catalog. Phone lines are open Monday thru Friday from 7:30 a.m. to 7:00 p.m. Central Time. You can also order online through the Interactive Network (iN). Click on Service, Tool and Equipment, and then Online Catalog. Click on Alignment, Wheel, and Brake Equipment, and then On-Car Brake Lathes. WARRANTY CLAIM INFORMATION None, this bulletin is for information only. FRONT BRAKE DISCS The following guidelines show the Kwik-Way lathe setup, the Accu-turn lathe setup is similar. Setting Up the Vehicle Put the transmission in Neutral. If you are not using the power drive system, start the engine, and let it warm up to its normal operating temperature so the idle speed will stabilize to its lowest rpm. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes - Brake Disc Refinishing Information > Page 6527 Raise the vehicle on a lift. Check for loose wheel bearings. You must replace loose wheel bearings before you refinish the brake discs. If you do not, the brake lathe will not correct for brake disc runout, resulting in an uneven finish and brake pulsation. Remove the front wheels, then reinstall the wheel nuts with flat washers to compensate for the removed wheel. Torque the wheel nuts to the required specification (see the appropriate service manual). Remove the caliper assembly. Use a wire or a S-hook to hold the caliper to the spring or damper tower. Do not kink the brake hose or use it to support the caliper. If you are not using the power drive system and the vehicle has ICS or VSA, make sure you install a brake pad spreader between the pads on the hanging caliper. Also, make sure the ICS or VSA is turned off anytime the engine is started. If the system is not turned off, the brakes could activate, causing the brake pads on the hanging caliper to hit each other or the caliper pistons to fall out. Install the vibration damper on the brake disc. If you are not using the power drive system, make sure you install the protective band around the wheel nuts. If you are not using the power drive system, use a fabric tie-down strap to secure the brake disc that is opposite to the one you are refinishing. If you are working on a Prelude with ATTS, do not use a tie-down strap; let both wheels turn freely. Mounting the Brake Lathe Remove the tool bed from the brake lathe, then mount the brake lathe to the steering knuckle with a Honda 1-piece speed mount. These mounts provide quicker, more accurate mounting, and can be ordered through the Honda Tool and Equipment Program (see ORDERING INFORMATION). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes - Brake Disc Refinishing Information > Page 6528 Honda 1-Piece Speed Mounts P/N KWY-108006000 (for most models), P/N KWY-108007500 (Odysseys, Pilots, and Ridgelines with two-piston calipers) Attaching the Power Drive System 1. Make sure the drive motor assembly on the power drive system is level with the brake disc. 2. Attach the mounting yoke to the brake disc, and secure it with one of the wheel nuts. Torque the wheel nut to the required specification (see the appropriate service manual). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes - Brake Disc Refinishing Information > Page 6529 3. Attach the driveshaft on the drive motor assembly to the mounting yoke, making sure the center line of the driveshaft is level with the spindle nut on the wheel hub. 4. Set the lower toggle switch on the drive motor assembly to FWD (counterclockwise rotation) or REV (clockwise rotation). Setting Up and Adjusting the Brake Lathe Use Kwik-Way cutting bits, P/N KWY-109109223, and the holding screws that come with them. These bits are stamped KW and are available through the Honda Tool and Equipment Program (see ORDERING INFORMATION). Before you use the brake lathe, inspect the tips of the cutting bits with a magnifying glass to make sure the tips are not worn out. Each bit has three tips. If a tip is worn, rotate the bit, and use a new tip. A worn tip produces a poor finish and may cause chattering. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes - Brake Disc Refinishing Information > Page 6530 Reinstall the tool bed on the brake lathe with the top of the cutting bits facing up and the feed knobs facing down. Adjust the tool bed until the brake disc is centered between the cutting bits. For proper refinishing, the brake disc must turn toward the top of the cutting bits. Do not set the cutting depth on the brake lathe to more than 0.2 mm (0.008 in.). This is two divisions on the cutting knob. Make sure you start your cut at least 3 mm (0.12 in.) beyond the worn area on the brake disc. If you are cutting larger diameter brake discs, make sure you use the 150 cutting bit holders. These bit holders, available through the Honda Tool and Equipment Program (see ORDERING INFORMATION), supersede the original bit holders and provide better cutting coverage for larger diameter brake discs. Each bit holder is clearly marked for proper installation on the tool holder. Cutting the Brake Disc To get the smoothest cut and the best brake disc finish, always use the slowest feed speed on the tool bed feed motor. Place the drive belt on the smallest pulley of the feed motor and on the largest pulley of the hand wheel. Make sure the lower toggle switch on the power drive system drive motor assembly is set to the proper rotation to turn the brake disc toward the top of the cutting bits. Plug the tool bed feed motor into the power outlet on the drive motor assembly, then turn on the drive motor with the upper toggle switch on the assembly. If you are not using the power drive system, make sure the transmission is in 1st gear (2nd gear on Preludes with ATTS) or Reverse and the engine is idling, but not at a fast idle. If the transmission and engine are at higher gears and speeds, you will damage the cutting bits. Turn on the tool bed feed motor, and snap it into place; there should be tension on the feed belt. Cut the brake disc until the cutting bits clear the outer edge of the disc. The cutting bits should produce a smooth, consistent finish with no chatter marks or grooves. If the disc did not clean up entirely on the first pass, reset the brake lathe and make a second pass. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes - Brake Disc Refinishing Information > Page 6531 Finishing the Job Remove the vibration damper and the protective band (if used). Use a micrometer to measure the thickness of the brake disc. Make sure the thickness is within the service manual specifications. Clean the brake disc with soapy water or brake cleaner, then wipe it dry. Use a vacuum cleaner to remove any dust or chips, but do not use compressed air. Unplug the tool bed feed motor from the drive motor assembly, and remove the mounting yoke from the brake disc. Remove the speed mount from the steering knuckle. Apply a small amount of Molykote 77 grease to the brake pad shims. Reinstall the caliper assembly. (If you did not use the power drive system, use the brake pad spreader to push the pistons back into the caliper.) Torque the nuts and bolts to the required specification (see the appropriate service manual). Refinish the other front brake disc using the same guidelines. Check the brake fluid level, then test-drive the vehicle to make sure the brake pedal is firm and does not pulsate. Lightly apply the brakes about 20 times during the test-drive to seat the brake pads. REAR BRAKE DISCS It is possible to use an on-car lathe on some models if the rear caliper mounts are low enough to clear the vehicle body. A power driver is needed for front drive models. Refinish rear brake discs on bench-mounted equipment if necessary. Follow the same guidelines you used for refinishing front brake discs, noting these differences: ^ Mount the brake lathe to the rear knuckle with the Honda 2-Piece Adapter (P/N KWY-1 08102504). You can order the 2-piece adapter through the Honda Tool and Equipment Program (see ORDERING INFORMATION). Disclaimer Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes - Brake Disc Refinishing Information > Page 6532 Brake Rotor/Disc: Technical Service Bulletins Brakes - Disc Refinishing Procedure Bulletin No. 86-020 Issue Date May 27, 1997 Model ALL Applicable To ALL Except 2WD Passport File Under BRAKES Brake Disc Refinishing (Supersedes 86-020, dated October 3, 1986) [NEW] * Brake disc replacement under warranty is not allowed unless the disc is beyond its maximum refinishing limit. If a disc is within its limit, it must be refinished. For front and rear brake disc maximum refinishing limit specifications, refer to section 19 of the appropriate service manual (section 5A2 for Passports). Front Brake Discs Whenever a front brake disc is replaced, it must be refinished on the car. Refinishing new front discs is included in the flat-rate time for disc replacement. To avoid brake vibration, always refinish front brake discs on the car with the Kwik-Way or Snap-on brake lathe. Purchasing information for these lathes is in Service Bulletin 87-034, Front Brake Disc Refinishing Equipment, filed in the Special Tools section. Follow these tips to get the best results from your on-car brake lathe. (For detailed instructions, refer to the lathe's operating manual.) ^ Before refinishing, warm the engine to normal operating temperature. ^ On 2WD vehicles, lift both front wheels off the ground. On 4WD vehicles, lift all four wheels off the ground. ^ On 4WD Passports, make sure that the hub nut is properly adjusted (with no end play) and the transmission is in 4H. ^ On Preludes with ATTS (Active Torque Transfer System), let both front wheels turn freely On other vehicles, use a tie-down strap to secure the disc opposite to the one being refinished. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes - Brake Disc Refinishing Information > Page 6533 ^ Install the vibration damper on the disc, and install the protective band around the wheel lug nuts. ^ Mount the lathe to the caliper bracket with Honda Quick-Mount Adapters. The adapters can be ordered through the Honda Tool and Equipment Program; contact Special Tools at 800-346-6327. The advantage of using the adapters is that they don't have to be removed from the lathe once they are installed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes - Brake Disc Refinishing Information > Page 6534 ^ Use the aligning bar tool to ensure that the lathe moves square to the center of the brake disc. The disc should turn toward the cutting bits. ^ Use "Kwik-Way" cutting bits (P/N KW109-1092-23, H/C 5418866) and the holding screws that come with them. These bits are stamped "K W." They can be purchased from American Honda using normal parts ordering procedures, or by contacting a Kwik-Way distributor. The Kwik-Way P/N is 109-1092-23. ^ Before using the lathe, inspect the tips of the cutting bits with a magnifying glass to make sure they are not worn out. Each bit has three tips. ^ Do not set the cutting depth on the lathe to more than 0.2 mm (0.008 in.) This is two divisions on the cutting knob. ^ To refinish, the transmission must be in first gear (D3 or D4, if the shift selector doesn't have a first gear position; second gear on Preludes with ATTS), with the engine at idle (not fast idle). If the transmission and engine are at higher gears and speeds, you will damage the cutting bits. Rear Brake Discs Refinish rear brake discs off the car with conventional disc refinishing equipment. WARRANTY CLAIM INFORMATION [NEW] None; information only. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Front Brake Rotor/Disc: Specifications Nominal Thickness 0.820 in Minimum Refinish Thickness 0.740 in Thickness Variation Parallelism 0.0006 in Lateral Runout 0.006 in Minimum Pad Thickness 0.060 in Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Front > Page 6537 Brake Rotor/Disc: Specifications Nominal Thickness 0.350 in Minimum Refinish Thickness 0.320 in Thickness Variation Parallelism 0.0006 in Lateral Runout 0.004 in Minimum Pad Thickness 0.060 in Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 6538 Brake Rotor/Disc: Service and Repair 1. Raise and support front of vehicle, then remove front wheels. 2. Raise spindle nut locking tab, then remove spindle nut. 3. Remove brake hose bracket mounting bolts. 4. Remove caliper and position aside. Do not allow caliper assembly to hang from brake hose. 5. Remove brake disc attaching screws, then thread two 8 x 1.25 x 12 mm bolts into attaching screw holes to push disc from hub. When tightening screws, turn only two turns at a time to prevent excessively cocking the brake disc. 6. Remove brake disc from knuckle. 7. Remove speed sensor wire bracket, then the speed sensor from knuckle. 8. Remove tie rod end cotter pin and nut. 9. Remove tie rod end using suitable tie rod end remover. 10. Remove lower ball joint cotter pin, then loosen ball joint nut half way. 11. Using ball joint remover tool No. 07MAC-SL00200, or equivalent, separate ball joint and lower arm. 12. Remove upper ball joint shield, then the cotter pin and nut. 13. Separate upper ball joint from upper arm using suitable ball joint remover. 14. Remove steering knuckle and hub assembly by sliding off driveshaft. 15. Remove hub from steering knuckle using suitable press. 16. Remove knuckle ring, circlip and splash guard from knuckle. 17. Press out wheel bearing from hub using driver tool No. 07749-0010000, attachment tool No. 07746-0010500 and base tool No. 07GAF-SE00401, or equivalents. 18. Remove outboard bearing inner race from hub. Fig. 2 Exploded View Of Steering Knuckle & Hub Assembly 19. Reverse procedure to install. Refer to Fig. 2 for tightening specifications. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications > Automatic Transaxle Brake Drum: Specifications Brake Drum Standard Inside Diameter 7.87 in Brake Drum Service Limit 7.91 in Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications > Automatic Transaxle > Page 6544 Brake Drum: Specifications Brake Drum Standard Inside Diameter 7.09 in Brake Drum Service Limit 7.13 in Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Removal Brake Drum: Service and Repair Removal Fig. 1 Rear Drum Brake Assembly 1. Refer to Fig. 1 when replacing brake shoes. 2. Raise and support rear of vehicle, then remove tire and wheel assemblies. 3. Loosen parking brake, then remove rear brake drums. 4. Remove tension pins by pushing retainer springs while turning. 5. Lower brake shoe assembly being careful not to damage wheel cylinder dust cover, then remove lower return spring. 5. Disconnect parking brake cable from parking brake lever, then remove brake shoe assembly. 7. Remove upper return spring, self-adjuster lever and spring, then separate brake shoes. 8. Remove wave washer, parking brake lever and pivot pin from brake shoe by removing the U-clip. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Removal > Page 6547 Brake Drum: Service and Repair Inspection 1. Inspect wheel cylinders for leakage, and brake linings for cracking, glazing, wear and contamination. 2. Measure brake lining thickness. Compare measurement with specifications. If brake lining thickness is less than specified, replace both shoes as a set. 3. Inspect brake drum for scoring, grooving and cracks. Replace as necessary. 4. Measure inside diameter of brake drum. Compare measurement with specifications. If refinishing limit stamped on drum is different than specified, use the specification on the drum. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Removal > Page 6548 Brake Drum: Service and Repair Installation 1. Apply brake cylinder grease to sliding surface of pivot pin, then insert pin into brake shoe. 2. Install parking brake lever and wave washer on pivot pin and secure with U-clip. Pinch U-clip securely to prevent pivot pin from coming out of brake shoe. 3. Connect parking brake cable to parking brake lever. 4. Apply grease to each sliding surface. Keep grease off of brake linings. Wipe off any excess grease. 5. Clean threaded portions of clevis pins A and B, then coat with grease. To shorten clevis pins, turn adjuster bolt. 6. Hook adjuster spring to adjuster lever first, then to brake shoe. Be careful not to damage wheel cylinder dust covers. 7. Install lower return spring, tension pins and retaining springs. 8. Install brake drum, then depress brake pedal several times to set the self adjusting brake. 9. Adjust parking brake as outlined under Parking Brake. 10. Install wheel and tire assemblies and lower vehicle. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Testing and Inspection Brake Shoe: Testing and Inspection 1. Inspect wheel cylinders for leakage, and brake linings for cracking, glazing, wear and contamination. 2. Measure brake lining thickness. Compare measurement with specifications. If brake lining thickness is less than specified, replace both shoes as a set. 3. Inspect brake drum for scoring, grooving and cracks. Replace as necessary. 4. Measure inside diameter of brake drum. Compare measurement with specifications. If refinishing limit stamped on drum is different than specified, use the specification on the drum. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Removal Brake Shoe: Service and Repair Removal Fig. 1 Rear Drum Brake Assembly 1. Refer to Fig. 1 when replacing brake shoes. 2. Raise and support rear of vehicle, then remove tire and wheel assemblies. 3. Loosen parking brake, then remove rear brake drums. 4. Remove tension pins by pushing retainer springs while turning. 5. Lower brake shoe assembly being careful not to damage wheel cylinder dust cover, then remove lower return spring. 5. Disconnect parking brake cable from parking brake lever, then remove brake shoe assembly. 7. Remove upper return spring, self-adjuster lever and spring, then separate brake shoes. 8. Remove wave washer, parking brake lever and pivot pin from brake shoe by removing the U-clip. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Removal > Page 6554 Brake Shoe: Service and Repair Installation 1. Apply brake cylinder grease to sliding surface of pivot pin, then insert pin into brake shoe. 2. Install parking brake lever and wave washer on pivot pin and secure with U-clip. Pinch U-clip securely to prevent pivot pin from coming out of brake shoe. 3. Connect parking brake cable to parking brake lever. 4. Apply grease to each sliding surface. Keep grease off of brake linings. Wipe off any excess grease. 5. Clean threaded portions of clevis pins A and B, then coat with grease. To shorten clevis pins, turn adjuster bolt. 6. Hook adjuster spring to adjuster lever first, then to brake shoe. Be careful not to damage wheel cylinder dust covers. 7. Install lower return spring, tension pins and retaining springs. 8. Install brake drum, then depress brake pedal several times to set the self adjusting brake. 9. Adjust parking brake as outlined under Parking Brake System / Adjustments. 10. Install wheel and tire assemblies and lower vehicle. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Specifications Wheel Cylinder: Specifications Backing Plate To Axle 47 ft.lb Banjo Bolt 25 ft.lb Parking Brake Nut 20 ft.lb Wheel Cylinder To Backing Plate 6.5 ft.lb Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > System Bleeding Brake Bleeding: Service and Repair System Bleeding Anti-Lock Brake System Anti-Lock Brake Bleeding See: With Anti-Lock Brakes (Using ALB Checker) With Anti-Lock Brakes (Using ALB Checker) Park vehicle on level ground with wheels blocked. When bleeding brakes, put manual transaxle in the Neutral position and automatic transaxle in the Park position. 1. With ignition switch Off, disconnect 6-P inspection connector from connector cover on the crossmember under passenger seat and connect it to anti-lock brake checker tool Nos. 07HAJ-SG0010A or 07HAJ-SG0010B, or equivalents. 2. Fill modulator reservoir to MAX level and install reservoir cap. 3. Start engine and allow it to idle for a few minutes, then shut engine off. Check fluid in modulator reservoir and refill to MAX level if necessary. Fig. 86 Bleeding High Pressure Fluid At Maintenance Bleeder 4. Bleed high pressure fluid from maintenance bleeder with bleeder wrench tool No. 07HAA-SG00101, or equivalent, Fig. 86. 5. Refill modulator reservoir to MAX level and install reservoir cap. 6. Turn mode selector switch on checker to 2. 7. While depressing brake pedal firmly, push start test switch to operate modulator. There should be kickback on brake pedal. If there is no kickback, repeat bleeding sequence as outlined above. 8. Turn mode selector switch on checker to 3, 4 and 5. At each test mode position, refill modulator reservoir to MAX level and install reservoir cap. 9. Refill modulator reservoir to MAX level and install reservoir cap. Disconnect ALB checker before driving car. A collision can result from a reduction, or complete loss of braking ability. Without Anti-Lock Brakes CAUTION: - Always use Genuine Honda DOT 3 Brake Fluid. Using a non-Honda brake fluid can cause corrosion and decrease the life of the system. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > System Bleeding > Page 6563 - Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid. - Do not spill brake fluid on the vehicle, it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water. NOTE: The reservoir on the master cylinder must be at the MAX (upper) level mark at the start of the bleeding procedure and checked after bleeding each brake caliper. Add fluid as required. 1. Make sure the brake fluid level in the reservoir is at the MAX (upper) level line. 2. Have someone slowly pump the brake pedal several times, then apply steady pressure. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > System Bleeding > Page 6564 3. Loosen the brake bleed screw to allow air to escape from the system. Then tighten the bleed screw securely. Brake Bleeding Sequence 4. Repeat the procedure for each wheel in the sequence shown until air bubbles no longer appear in the fluid. 5. Refill the master cylinder reservoir to the MAX (upper) level line. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > System Bleeding > Page 6565 Brake Bleeding: Service and Repair ABS Hydraulic Component Bleeding and Fluid Service Relieving Accumulator/Line Pressure WARNING: Use the Bleeder T-wrench before disassembling the parts shaded in the illustration Collecting High-pressure Fluid Into Reservoir Through Maintenance Bleeder - Open the hood. - Remove the red cap from the bleeder on the modulator body. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > System Bleeding > Page 6566 Fig. 81 Brake System Pressure Relief - Install the special tool on the maintenance bleeder, and turn it out slowly 90° to collect high-pressure fluid into the reservoir. Turn the special tool out one complete turn to drain the brake fluid thoroughly. - Retighten the maintenance bleeder, and discard the fluid. - Reinstall the red cap. Brake Fluid Change Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > System Bleeding > Page 6567 Fig. 85 Draining Brake Fluid Reservoir W/Syringe 1. Brake fluid may be sucked out through the top of modulator reservoir with a syringe. It may also be drained through the pump joint after disconnecting pump hose, Fig. 85. 2. Loosen master cylinder bleed screw and pump brake pedal to drain brake fluid from master cylinder. WARNING: - High-pressure fluid will squirt out if the shaded hose and pipe are removed. - To drain high-pressure brake fluid. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Banjo Bolt 25 ft.lb Front Caliper Bleed Screw 6 ft.lb Front Caliper Bolt (Bottom) 20 ft.lb Front Caliper Bolt (Top) 25 ft.lb Front Caliper Bracket Bolt 80 ft.lb Parking Brake Nut 20 ft.lb Rear Caliper Bleed Screw 7 ft.lb Rear Caliper Bracket Bolt 28 ft.lb Rear Caliper Mounting Bolt 17 ft.lb Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front Brake Caliper: Service and Repair Front Removal Ensure dirt or other foreign matter is not allowed to contaminate brake fluid. Do not mix different types of brake fluid, as they might not be compatible. Fig. 2 Front Pin Siding Disc Brake Caliper 1. Refer to Fig. 2 when replacing calipers. 2. Raise and support front of vehicle, then remove wheel and tire assemblies. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6573 Fig. 19 Brake Line Banjo Bolt 3. Remove banjo bolt and disconnect brake hose from caliper, Fig. 11. 4. Remove caliper bolts, then the caliper. Installation 1. Install caliper and caliper bolts. 2. Connect brake hose to caliper, then install banjo bolt. 2. Bleed front brakes, then install wheel and tire assemblies. Disassembly Ensure dirt or other foreign matter is not allowed to contaminate brake fluid. Do not mix different types of brake fluid, as they might not be compatible. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6574 Fig. 2 Front Pin Siding Disc Brake Caliper 1. Refer to Fig. 2 when overhauling calipers. 2. Remove caliper assembly from vehicle. Fig. 12 Pad Spring 3. Remove pad spring from caliper body, if equipped, Fig. 12. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6575 Fig. 19 Brake Line Banjo Bolt 4. Place wooden block or shop rag in caliper opposite piston, then carefully remove piston from caliper by applying air pressure through brake line hole with OSHA-approved 30 psi nozzle, Fig. 11. 5. Remove boot clip, if equipped, then the piston boot and piston seal. Assembly Ensure dirt or other foreign matter is not allowed to contaminate brake fluid. Do not mix different types of brake fluid, as they might not be compatible. 1. Clean piston and caliper bore with brake fluid, then inspect for wear or damage. 2. Apply brake cylinder grease to new piston seal and install seal in cylinder groove. 3. Install piston boot, then the boot retaining clip. 4. Lubricate caliper cylinder and piston with brake fluid, then install piston in cylinder with dished end facing in. 5. Install pad spring in caliper housing. 6. Install caliper assembly. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6576 Brake Caliper: Service and Repair Rear Disassembly - WARNING: Never use an air hose or dry brush to clean brake assemblies. - Use an OSHA-approved vacuum cleaner to avoid breathing brake dust. - Contaminated brake discs or pads reduce stopping ability. CAUTION: - Do not spill brake fluid on the car; it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water. - To prevent spills, cover the hose joints with rags or shop towels. - Clean all parts in brake fluid and air dry; blow out all passages with compressed air. 1. Remove the caliper shield. 2. Remove the lock pin and clevis pin. Remove the cable clip and disconnect the cable from the parking brake arm. 3. Remove the banjo bolt and two sealing washers. 4. Remove the two caliper mounting bolts and caliper body from the bracket. 5. Remove the pad spring from the caliper body. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6577 6. Remove the piston by rotating the piston counterclockwise with the special tool and remove the piston boot. CAUTION: Avoid damaging the piston. 7. Remove the piston seal. CAUTION: Take care not to damage the cylinder bore. 8. Install the special tool between the caliper body and spring cover. CAUTION: Be careful not to damage the inside of the caliper cylinder during caliper disassembly. 9. Position the locknuts as shown, then turn the shaft until the plate just contacts the caliper body. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6578 NOTE: Do not compress the spring under the spring cover. 10. Turn the shaft clockwise 1/4-1/2 turn to compress the adjusting spring B in the caliper body. CAUTION: To prevent damage to the inner components, do not turn the shaft more than 1/2 turn. 10. Turn the shaft clockwise 1/4-1/2 turn to compress the adjusting spring B in the caliper body. CAUTION: To prevent damage to the inner components, do not turn the shaft more than 1/2 turn. 11. Lower the locknuts fully and tighten the locknuts securely. NOTE: Keep the locknuts in this position until you reinstall the circlip. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6579 12. Remove the circlip with snap ring pliers. 13. Hold the plate with your fingers and turn the shaft counterclockwise. Remove the special tool from the caliper. 14. Remove the adjusting bolt. 15. Remove the spring cover, adjusting spring B, spacer, bearing A and cup from the adjusting bolt. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6580 16. Remove the sleeve piston, and remove the pin from the cam. 17. Remove the return spring. 18. Remove the parking lever and cam as an assembly from the caliper body. CAUTION: Do not loosen the parking nut with the cam installed in the caliper body. If the lever and shalt must be separated, hold the lever in a vise and loosen the parking nut. 19. Remove the cam boot. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6581 Reassembly WARNING: - Never use an air hose or dry brush to clean brake assemblies. - Use an OSHA-approved vacuum cleaner to avoid breathing brake dust. - Contaminated brake discs or pads reduce stopping ability. - When reusing the pads, install them in their original positions to prevent loss of braking efficiency. CAUTION: - Do not spill brake fluid on the car; it may damage the paint: if brake fluid does contact the paint, wash it off immediately with water. - To prevent spills, cover the hose joints with rags or shop towels. - Clean all parts in brake fluid and air dry; blow out all passage with compressed air. - Before reassembling, check that all parts are free of dust and other foreign particles. - Replace parts with new ones whenever specified to do so. - Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid. - Do not mix different brands of brake fluid as they may not be compatible. - Do not reuse the drained fluid. Use only clean DOT 3 or 4 brake fluid. NOTE: - Coat piston, piston seal, and caliper bore with clean brake fluid. - Replace all rubber parts with new ones whenever disassembled. 1. Pack all cavities of the needle bearing with recommended grease. . Coat the new cam boot with recommended grease and install it in the caliper body. 3. Apply recommended grease to the pin contacting area of the cam and install the cam and lever assembly into the caliper body. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6582 4. Install the return spring. CAUTION: - When the cam and lever were separated, be sure to assemble them before installing the cam in the caliper body. Install the lever and spring washer apply locking agent to the threads, and tighten the parking nut while holding the lever with a vise. - Avoid damaging the cam boot since it must be installed before the cam. - When installing the cam, do not allow the cam boot lips to turn outside in. 5. Install the pin in the cam. 6. Apply recommended grease to the new O-ring and install it on the sleeve piston. 7. Install the sleeve piston so the hole in the bottom of the piston is aligned with the pin in the cam and two pins on the piston are aligned with the holes in the caliper. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6583 8. Coat a new cup with recommended grease, and install it with its groove facing the bearing A side of the adjusting bolt. 9. Fit the bearing A, spacer, adjusting spring B and spring cover on the adjusting bolt, and install them in the caliper cylinder. 10. Install the special tool on the spring cover and turn the shaft until the locknut contacts the plate 11. Check that the flared end of the spring cover is below the circlip groove. 12. Install the circlip in the groove, then remove the special tool. NOTE: Check that the circlip is seated in the groove properly. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6584 13. Coat a new piston seal with silicone grease and in stall it in the caliper. 14. Apply brake cylinder grease (P/N: 08733-BO2OE) or equivalent rubber grease to the sealing lips and inside of a new piston boot, and install it in the caliper. 15. Coat the outside of the piston with brake fluid and install it on the adjusting bolt while rotating it clockwise with the special tool. 16. Install the pad spring on the caliper. 17. Install the brake pad retainers and brake pads. CAUTION: Avoid damaging the piston and piston boot. 18. Align the cutout in the piston with the tab on the inner pad. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6585 19. Install the caliper on the caliper bracket and tighten the caliper mounting bolts. 20. Connect the brake hose to the caliper with new sealing washers and tighten the banjo bolt. 21. Insert the cable through the arm and connect the cable to the lever with the clevis pin and lock pin. Install the cable clip securely. 22. Fill the brake reservoir up and bleed the brake system. 23. Operate the brake pedal several times, then adjust the parking brake. 24. After installation, perform the following checks. - Check for leaks at hose and line joints or connections, and retighten if necessary. - Check the parking brake lever for operation and adjust if necessary. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications Fluid type DOT 3 or 4 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Accumulator > Component Information > Description and Operation Brake Fluid Accumulator: Description and Operation The accumulator is a pneumatic type which accumulates high pressure brake fluid fed from the pump incorporated in the power unit. When the anti-lock brake system operates, the accumulator feeds high pressure brake fluid to the modulator valve via the inlet side of the solenoid valve. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Accumulator > Component Information > Service and Repair > Removal and Installation Brake Fluid Accumulator: Service and Repair Removal and Installation Fig. 95 Accumulator Replacement Refer to Fig. 95 when replacing accumulator. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Accumulator > Component Information > Service and Repair > Removal and Installation > Page 6594 Brake Fluid Accumulator: Service and Repair Disposal WARNING: The accumulator contains high pressure nitrogen gas. Do not puncture, expose to flame or attempt to disassemble the accumulator or it may explode. Fig. 79 Relieving Nitrogen Gas From Accumulator For Disposal 1. Secure accumulator in a vise with relief plug pointing straight up, Fig. 84. 2. Slowly turn plug 3 1/2 turns and wait three minutes for all pressure to escape. 3. Remove plug completely and dispose of accumulator unit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations Brake Fluid Level Sensor/Switch: Locations Left Rear Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 6598 Brake Fluid Level Sensor/Switch: Description and Operation The brake system indicator light comes ON to alert the driver that the parking brake is applied, or that the brake fluid level is low. It also comes ON as a bulb test when the engine is cranked. With the ignition switch in ON (II) or START (III), voltage is applied through fuse 15 to the brake system light. If the brake fluid level is low, the brake fluid level switch closes, providing ground to the circuit. The brake system light then comes ON, alerting the driver to a low brake fluid level in the brake master cylinder. (Check brake pad wear before adding fluid.) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch > Component Information > Description and Operation Brake Fluid Pressure Sensor/Switch: Description and Operation The pressure switch monitors the pressure accumulation in the accumulator and is turned off when the pressure becomes lower than a prescribed level. When the pressure switch is turned off, the switching signal is sent to the control unit. Upon receiving the signal, the control unit activates the pump motor relay to operate the motor. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Service and Repair Brake Proportioning/Combination Valve: Service and Repair The dual portioning valve is not a serviceable component and must be replaced if found to be faulty. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Power Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Locations Power Unit: Locations Right Rear Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Power Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Description and Operation > Brake Pressure Modulator Valve Power Unit: Description and Operation Brake Pressure Modulator Valve Modulators and solenoid valves are integrated in the modulator unit. The modulators for front and rear brakes are of independent construction and are positioned vertically. The modulators for rear brakes are provided with a proportioning control valve to prevent the rear wheels from locking when the anti-lock brake system is malfunctioning or not activated. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Power Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Description and Operation > Brake Pressure Modulator Valve > Page 6610 Power Unit: Description and Operation Power Unit The power unit consists of a motor and a plunger pump. Since an eccentric bearing is positioned on the end of the motor shaft, the rotation of the motor provides the reciprocating motion of the plunger. The brake fluid is thus pressurized and fed to the accumulator. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Power Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Service and Repair > Brake Pressure Modulator Valve Power Unit: Service and Repair Brake Pressure Modulator Valve CAUTION: Do not spill brake fluid on the car; it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Power Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Service and Repair > Brake Pressure Modulator Valve > Page 6613 Relieving Accumulator/Line Pressure WARNING: Use the Bleeder T-wrench before disassembling the parts shaded in the illustration. 1. Open the hood. 2. Remove the red cap from the bleeder on the modulator body. 3. Install the special tool on the maintenance bleeder and turn it out slowly 90°to collect high-pressure fluid into the reservoir. Turn the special tool out one complete turn to drain the brake fluid thoroughly. 4. Retighten the maintenance bleeder and discard the fluid. 5. Reinstall the red cap. Reservoir Brake Fluid Draining 1. Draining brake fluid from modulator tank: The brake fluid may be sucked out through the top of the modulator tank with a syringe. It may also be drained through the pump joint after disconnecting the pump hose. 2. Draining brake fluid from master cylinder: Loosen the bleed screw and pump the brake pedal to drain the brake fluid from the master cylinder. WARNING: High-pressure fluid will squirt out if the shaded hose and pipe are removed. - To drain high-pressure brake fluid, follow the procedure for releaving accumulator line pressure. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Power Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Service and Repair > Brake Pressure Modulator Valve > Page 6614 Modulator/Pump Removal/Installation CAUTION: - Be careful not to bend or damage the brake pipes when removing the modulator unit. - Do not spill brake fluid on the car; it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water. - To prevent spills, cover the hose joints with rags or shop towels. - Before reassembling, check that all parts are free of dust and other foreign particles. - Do not mix different brands of brake fluid as they may not be compatible. - Do not reuse the drained fluid. Use only clean DOT 3 or 4 brake fluid. - When connecting the brake pipes, make sure that there is no interference between the brake pipes and other parts. 1. Remove the battery and battery tray. 2. Disconnect the solenoid, motor and pressure switch connectors. 3. Disconnect the brake pipes from the modulator unit. 4. Remove the mounting bolts and nut, then remove the modulator/ABS pump assembly from the frame. 5. Install the modulator/ABS pump assembly in the reverse order of removal. 6. After installation, bleed the air from the system. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Power Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Service and Repair > Brake Pressure Modulator Valve > Page 6615 Modulator/Pump Index/Torque Before removing the modulator-to-pump high-pressure line, be sure to relieve the pressure fluid from the maintenance bleeder. Refer to Relieving Accumulator/Line Pressure above. CAUTION: - Do not spill brake fluid on the car; it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water. - To prevent spills, cover the hose joints with rags or shop towels. - Before reassembling, check that all parts are free of dust and other foreign particles. - Do net mix different brands of brake fluid as they may not be compatible. - Do not reuse the drained fluid. Use only clean DOT 3 or 4 brake fluid. - Do not try to disassemble the modulator unit and pump assembly. Replace the modulator unit as an assembly if it is defective. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Power Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Service and Repair > Brake Pressure Modulator Valve > Page 6616 Solenoids Leak Test NOTE: If a solenoid leaks excessively, the brake fluid level in the modulator reservoir tank will rise when operating the ABS motor. The modulator reservoir may also overflow. 1. Connect an ohmmeter between the YEL and YEL terminals of the pressure switch connector. 2. Attach the positive (+) lead of a fully charged 12 V battery to the RED/WHT terminal of the motor connector and negative (-) lead to the GRN terminal, and install a switch between negative lead and GRN terminal as shown. 3. Turn the switch on to allow sufficient pressure to build up within the accumulator and check for continuity. If the ohmmeter shows continuity (pressure switch turned on), run the motor for 10 seconds more, then turn the switch off. Check if the solenoid hisses or squeaks. Replace the modulator unit if the solenoid hisses or squeaks. - Check the pressure switch for continuity within 30 minutes. It is normal if there is continuity. If there is no continuity, a solenoid is faulty or there is a high-pressure line leak. Accumulator Replacement - Before removing the modulator-to-accumulator high pressure line, be sure to relieve the pressure fluid from the maintenance bleeder. Refer to Relieving Accumulator/Line Pressure above. 1. Loosen the flare nuts and remove the accumulator pipe 2. Remove the three mounting bolts and the accumulator from the modulator unit. 3. Install a new accumulator in the reverse order of removal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Power Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Service and Repair > Brake Pressure Modulator Valve > Page 6617 4. Bleed the air from the high-pressure line. Refer to Air Bleeding with ALB Checker below. Disposal The accumulator contains high pressure nitrogen gas. Do not puncture, expose to the flame, or attempt to disassemble the accumulator or it may explode and severe personal injury may result. 1. Secure the accumulator in a vise so that the relief plug points straight up. 2. Slowly turn the plug three and a half turns and then wait three minutes for all pressure to escape. 3. Remove the plug completely and dispose of the accumulator. Bleeding Air Bleeding with ALB Checker CAUTION: - Do not spill brake fluid on the car; it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water. - Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid. - Do not mix different brands of brake fluid as they may not be compatible. - Do not reuse the drained fluid. Use only clean DOT 3 or 4 brake fluid. 1. Place the vehicle on level ground with the wheels blocked. Put the transmission in neutral for manual transmission models, and in (P) position for automatic transmission models. Release the parking brake. 2. Disconnect the ABS inspection connector (6P) from the cross-member under the passenger's seat and connect the ABS inspection connector (6P) to the ALB checker. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Power Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Service and Repair > Brake Pressure Modulator Valve > Page 6618 3. Fill the modulator reservoir to the MAX level line and install the reservoir cap. 4. Start the engine and allow it to idle for a few minutes, then stop it. Check the fluid level in the modulator reservoir and refill to the MAX level line if necessary. 5. Bleed high-pressure fluid from the maintenance bleeder with the special tool. 6. Refill the modulator reservoir to the MAX level line and install the reservoir cap. 7. Turn the Mode Selector switch of the checker to 2. 8. While depressing the brake pedal firmly, push the Start Test switch to operate the modulator. There should be kickback on the brake pedal. If not, repeat steps 5 to 8. NOTE: Continue to depress the brake pedal firmly when operating the checker. 9. Turn the Mode Selector to 3, 4, and 5. Perform step 8 for each of the test mode positions. 10. Refill the modulator reservoir to the MAX level line and install the reservoir cap. WARNING: Disconnect the ALB check before driving the car. A collision can result from a reduction, or complete loss of braking ability causing severe personal injury or death. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Power Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Service and Repair > Brake Pressure Modulator Valve > Page 6619 Power Unit: Service and Repair Power Unit Fig. 104 Power Unit Replacement Refer to Fig. 104 when replacing power unit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation Brake Master Cylinder: Description and Operation A tandem master cylinder is used in order to improve safety of the braking system. In addition, a center valve method is introduced to match the anti-lock brake operation. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Adjustments > Pushrod Clearance Brake Master Cylinder: Adjustments Pushrod Clearance Master cylinder pushrod-to-piston clearance must be checked and adjusted before installing master cylinder. Fig. 17 Adjusting Pushrod Adjustment Gauge Bolt 1. Using pushrod adjustment gauge tool No. 07JAG-SD40100, or equivalent, adjust bolt so top of it is flush with end of master cylinder piston, Fig. 1. 2. Install master cylinder rod seal between pushrod bolt adjustment gauge and brake booster. 3. Without disturbing position of adjusting bolts, install gauge upside down on booster and torque nuts to 11 ft. lbs. Fig. 2 Measuring Pushrod Clearance 4. Connect booster inline with a vacuum gauge, and maintain an engine speed that will deliver 20 inches of vacuum. Then, using a feeler gauge, measure clearance between gauge body and adjusting nut, Fig. 2. Clearance should be 0.020 inches. 5. If clearance is incorrect, loosen star locknut and turn adjuster in or out to adjust. Hold clevis while adjusting, then tighten star locknut securely. 6. After adjustment, loosen clevis end pushrod locknut and turn pushrod to obtain correct pedal height. Adjust pedal to floor height, to the following specifications: a. On models with manual transaxle, 6.30 inches; with automatic transaxle, 6.50 inches. 7. Adjust brake light switch. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Adjustments > Pushrod Clearance > Page 6625 Brake Master Cylinder: Adjustments Pushrod Length Fig. 3 Pushrod Length Install locknut and pushrod yoke on pushrod, then adjust pushrod length Fig. 3. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Adjustments > Page 6626 Brake Master Cylinder: Service and Repair 1. Remove master cylinder reservoir cap, then the brake fluid by sucking out through top of reservoir with suitable syringe. 2. Disconnect brake lines from master cylinder, then all necessary electrical connectors. 3. Remove nuts retaining master cylinder to brake booster. 4. Remove master cylinder. 5. Reverse procedure to install. After installation is complete, fill master cylinder with DOT 3 or 4 brake fluid, then bleed brakes. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Specifications Wheel Cylinder: Specifications Backing Plate To Axle 47 ft.lb Banjo Bolt 25 ft.lb Parking Brake Nut 20 ft.lb Wheel Cylinder To Backing Plate 6.5 ft.lb Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations > Parking Brake Switch Parking Brake Warning Switch: Locations Parking Brake Switch Below Rear Console Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations > Parking Brake Switch > Page 6635 Parking Brake Warning Switch: Locations Parking Pin Switch Below Center Console Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Testing and Inspection > Functional Test Vacuum Brake Booster: Testing and Inspection Functional Test 1. With engine stopped, depress brake pedal several times, then depress pedal hard and hold for 15 seconds. If pedal sinks, master cylinder, brake line or brake caliper is faulty. 2. With brake pedal depressed, start engine. If pedal sinks slightly, vacuum booster is operating. If pedal height does not vary, booster or check valve is faulty. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Testing and Inspection > Functional Test > Page 6641 Vacuum Brake Booster: Testing and Inspection Leak Test 1. With engine running, depress brake pedal and hold, then stop engine. If pedal height does not vary with brake pedal depressed for 30 seconds, vacuum booster is operating. If pedal rises, booster is faulty. 2. Depress brake pedal several times with normal pressure. When pedal is first depressed, it should be low. As pedal is depressed, pedal height should gradually rise. If pedal height does not vary, check booster check valve. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Testing and Inspection > Functional Test > Page 6642 Vacuum Brake Booster: Testing and Inspection Check Valve Test 1. Disconnect brake booster vacuum hose at booster. 2. Start engine and allow to idle. 3. Vacuum should be indicated, if not, check valve is faulty. 4. Replace check valve and retest. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Testing and Inspection > Page 6643 Vacuum Brake Booster: Adjustments NOTE: - The master cylinder pushrod-to-piston clearance must be checked and adjustments made, if necessary, before installing the master cylinder. - ABS type is shown, conventional brake type is similar. 1. Set the special tool on the master cylinder body; push in the center shaft until the top of it contacts the end of the secondary piston by turning the adjusting nut. 2. Without disturbing the center shaft's position, install the special tool upside down on the booster. 3. Install the master cylinder nuts, and tighten to the specified torque. 4. Connect the booster in-line with a vacuum gauge 0 - 101 kPa (0 - 760 mmHg, 30 in.Hg) to the booster's engine vacuum supply, and maintain an engine speed that will deliver 66 kPa (500 mmHg, 20 in.Hg) vacuum. 5. With a feeler gauge, measure the clearance between the gauge body and the adjusting nut as shown. Clearance: 0 - 0.4 mm (0 - 0.02 inch) NOTE: If the clearance between the gauge body and adjusting nut is 0.4 mm (0.02 inch), the pushrod-to-piston clearance is 0 mm. However, if the clearance between the gauge body and adjusting nut is 0 mm, the pushrod-to-piston clearance is 0.4 mm (0.02 inch) or more. Therefore, it must be adjusted and rechecked. 6. If clearance is incorrect, loosen the star locknut, and turn the adjuster in or out to adjust. NOTE: Adjust the clearance while the specified vacuum is applied to the booster. - Hold the clevis while adjusting. 7. Tighten the star locknut securely. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Testing and Inspection > Page 6644 8. Remove the special tool. Brake Booster Length With Booster Removed 9. Adjust the pushrod length as shown if the booster is removed. 10. Install the master cylinder. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Removal and Installation Vacuum Brake Booster: Service and Repair Removal and Installation 1. Remove master cylinder as outlined under Master Cylinder, Brakes. 2. Disconnect vacuum hose from booster, then remove vacuum hose bracket. 3. Loosen pushrod locknut, then remove the cotter pin and clevis pin. 4. Remove clevis from operating rod of booster. 5. Remove four booster mounting nuts, then remove booster from engine compartment. 6. Reverse procedure to install. Adjust pushrod length before installing booster. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Removal and Installation > Page 6647 Vacuum Brake Booster: Service and Repair Disassembly and Assembly Do not disassemble brake booster; if replacement is required, replace entire booster assembly. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Locations ABS Main Relay: Locations Fuse/Relay Information-Under-hood ABS Fuse/Relay Box Right Side Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Brake Fluid Pump Relay > Component Information > Locations Brake Fluid Pump Relay: Locations Fuse/Relay Information-Under-hood ABS Fuse/Relay Box Right Side Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations Electronic Brake Control Module: Locations Right Side Of Trunk Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 6658 Electronic Brake Control Module: Description and Operation The main function section of the control unit performs calculations on the basis of the signals from each speed sensor. It controls the operation of the anti-lock brake system by putting the solenoid valves in the modulator unit into action for each front brake and for the two rear brakes. The sub-function section gives driving signals to the pump motor and also gives self-diagnosis signals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 6659 Electronic Brake Control Module: Service and Repair Fig. 90 Control Unit Replacement Refer to Fig. 90 when replacing the control unit. 1. Remove right side trunk trim panel. 2. Disconnect control unit connectors. 3. Remove control unit mounting bolts, then the control unit. When control unit mounting bolts are removed, the control unit's memory is cleared. 4. Reverse procedure to install. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Fail Safe Relay, ABS / Traction Control > Component Information > Locations > Front Fail Safe Relay: Locations Front Right Side Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Fail Safe Relay, ABS / Traction Control > Component Information > Locations > Front > Page 6664 Fail Safe Relay: Locations Rear Right Side Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations Brake Fluid Level Sensor/Switch: Locations Left Rear Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 6669 Brake Fluid Level Sensor/Switch: Description and Operation The brake system indicator light comes ON to alert the driver that the parking brake is applied, or that the brake fluid level is low. It also comes ON as a bulb test when the engine is cranked. With the ignition switch in ON (II) or START (III), voltage is applied through fuse 15 to the brake system light. If the brake fluid level is low, the brake fluid level switch closes, providing ground to the circuit. The brake system light then comes ON, alerting the driver to a low brake fluid level in the brake master cylinder. (Check brake pad wear before adding fluid.) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Description and Operation Brake Fluid Pressure Sensor/Switch: Description and Operation The pressure switch monitors the pressure accumulation in the accumulator and is turned off when the pressure becomes lower than a prescribed level. When the pressure switch is turned off, the switching signal is sent to the control unit. Upon receiving the signal, the control unit activates the pump motor relay to operate the motor. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Parking Brake Switch Parking Brake Warning Switch: Locations Parking Brake Switch Below Rear Console Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Parking Brake Switch > Page 6677 Parking Brake Warning Switch: Locations Parking Pin Switch Below Center Console Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Front Wheel Speed Sensor: Locations Front Behind Left Front Wheel (Right Similar) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Front > Page 6682 Wheel Speed Sensor: Locations Rear Behind Left Rear Wheel (Right Similar) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 6683 Wheel Speed Sensor: Description and Operation WHEEL SPEED SENSOR The speed sensor is a non-contact type which detects the rotating speeds of the wheel. It is composed of a permanent magnet and coil. When the gear pulsers at each wheel turn, the magnetic coil in the speed sensor alternates, generating voltages with frequency in proportion to wheel rotating speed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Testing and Inspection > Toothed Ring Wheel Speed Sensor: Testing and Inspection Toothed Ring INSPECTION OF THE TOOTHED RING 1. Check the front and rear pulser for chipped or damaged teeth. 2. Measure the air gap between the wheel sensor and pulser all the way around while rotating the pulser. Standard: 0.4 - 1.0 mm (0.02 - 0.04 inch) NOTE: If the gap exceeds 1.0 mm (0.04 inch), the probability is a distorted suspension arm which should be replaced. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Testing and Inspection > Toothed Ring > Page 6686 Wheel Speed Sensor: Testing and Inspection Wheel Speed Sensor TESTING THE WHEEL SPEED SENSOR 1. Check pulser for chipped or damaged teeth and replace as necessary. Fig. 82 Measureing Front Speed Sensor Air Gap 2. Measure air gap between sensor and pulser all the way around while rotating driveshaft by hand, Fig. 82. If gap exceeds its maximum specification at any point, the knuckle is most likely distorted and should be replaced. Air gap should be 0.016-0.039 inches. WHEEL SENSOR SIGNAL CONFIRMATION 1. With ignition switch off, disconnect 6-P inspection connector from connector cover on crossmember under passenger seat and connect it to anti-lock brake checker tool Nos. 07HAJ-SG0010A or 07HAJ-SG0010B, or equivalents. 2. Raise and support vehicle so all four wheels are off ground. 3. Turn ignition switch to on position, then turn mode selector switch on anti-lock brake checker to 0. 4. With transaxle in Neutral position, rotate each wheel at least one revolution per second and confirm that its respective monitor light on the checker blinks as wheel is rotating. Rotating wheel too slowly will produce only weak blinks of monitor lights. Perform tests in shaded area, as monitor lights may be difficult to see in bright sunlight. If the front wheels won't spin fast enough to get monitor indication, start engine and slowly accelerate and decelerate front wheels. 5. If any monitor light fails to blink, check the suspected sensor, its air gap, wiring and connectors. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor: Service and Repair Front Fig. 108 Front Speed Sensor Replacement Refer to Fig. 108 when replacing front speed sensor. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 6689 Wheel Speed Sensor: Service and Repair Rear Fig. 113 Rear Speed Sensor Replacement Refer to Fig. 113 when replacing rear speed sensor. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations Clutch Switch: Locations Behind Left Side Of Dash Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Testing and Inspection > Hitachi Starters Clutch Switch: Testing and Inspection Hitachi Starters 1. Remove instrument panel lower cover and left knee bolster. 2. Disconnect connector from switch. 3. With clutch pedal released, check continuity between both terminals. No continuity should be found. If continuity is found, replace or adjust switch as necessary. 4. With clutch pedal depressed, check continuity between both terminals. Continuity should be found. If no continuity is found, replace or adjust switch as necessary. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Testing and Inspection > Hitachi Starters > Page 6697 Clutch Switch: Testing and Inspection Mitsuba Starters 1. Remove instrument panel lower cover and left knee bolster. 2. Disconnect connector from switch. 3. With clutch pedal released, check continuity between both terminals. No continuity should be found. If continuity is found, replace or adjust switch as necessary. 4. With clutch pedal depressed, check continuity between both terminals. Continuity should be found. If no continuity is found, replace or adjust switch as necessary. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Testing and Inspection > Hitachi Starters > Page 6698 Clutch Switch: Testing and Inspection Nippondenso Starters 1. Remove instrument panel lower cover and left knee bolster. 2. Disconnect connector from switch. 3. With clutch pedal released, check continuity between both terminals. No continuity should be found. If continuity is found, replace or adjust switch as necessary. 4. With clutch pedal depressed, check continuity between both terminals. Continuity should be found. If no continuity is found, replace or adjust switch as necessary. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch Ignition Switch Lock Cylinder: Technical Service Bulletins Starting System - Unable To Key In Ignition Switch Can't Turn Ignition Switch? Check for Locked Steering Got a service customer complaining he or she can't turn the ignition switch to start the engine? The reason could just be the steering column lock pin is engaged with the front wheels turned. Here's what typically happens: Some folks use the steering wheel to help support themselves while climbing in or out of the vehicle. This is very common among elderly or disabled drivers. Doing this turns the front wheels, which twists the tires against the ground. The twisted tires apply torque to the steering column. With the ignition switch in LOCK (0), the steering column lock pin is engaged. But the applied torque on the steering column binds the lock pin, making it tough to turn the ignition switch. The ignition switch won't turn to ON (II) if the lock pin isn't disengaged from the steering column. Tell your customer there's nothing wrong with the ignition switch itself. All he or she needs to do is turn the steering wheel from side to side while turning the switch. This usually releases the lock pin so the engine can be started. In some cases, though, your customer may need to give a good tug on the wheel. This could easily happen when parking on a hill and the wheels are turned sharply before the engine is shut off. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Behind Left Side Of Dash Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection > Hitachi Starters Starter Relay: Testing and Inspection Hitachi Starters 1. Remove and disconnect starter relay. Fig. 5 Starter Relay Terminal Locations 2. Apply battery voltage to C and D terminals of relay, Fig. 5. 3. Check continuity between A and B terminals of relay. Continuity should exist. 4. Disconnect battery voltage. There should be no continuity between A and B terminals of relay. 5. If relay does not operate as specified, replace relay. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection > Hitachi Starters > Page 6710 Starter Relay: Testing and Inspection Mitsuba Starters 1. Remove and disconnect starter relay. Fig. 10 Starter Relay Terminal Locations 2. Apply battery voltage to C and D terminals of relay, Fig. 10. 3. Check continuity between A and B terminals of relay. Continuity should exist. 4. Disconnect battery voltage. There should be no continuity between A and B terminals of relay. 5. If relay does not operate as specified, replace relay. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection > Hitachi Starters > Page 6711 Starter Relay: Testing and Inspection Nippondenso Starters 1. Remove and disconnect starter relay. Fig. 13 Starter Motor Terminal Locations 2. Apply battery voltage to C and D terminals of relay, Fig. 13. 3. Check continuity between A and B terminals of relay. Continuity should exist. 4. Disconnect battery voltage. There should be no continuity between A and B terminals of relay. 5. If relay does not operate as specified, replace relay. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Battery > Component Information > Technical Service Bulletins > Electrical - GR8 Battery Diagnostic Station Update Info. Battery: Technical Service Bulletins Electrical - GR8 Battery Diagnostic Station Update Info. 09-060 February 12, 2011 Applies To: ALL GR8 Battery Diagnostic Station Update Information (Supersedes 09-060, dated January 19, 2010, to revise the information marked by the asterisks) REVISION SUMMARY *Under GR8 UPDATE INSTRUCTIONS, step 9 was updated.* INTRODUCTION The software for the GR8 Battery Diagnostic Station is updated periodically to fix software bugs and enhance the tool's function. You can now use the Midtronics GR8 update wizard to download software and firmware to your GR8 using a PC and the Internet. It is extremely important to use the latest GR8 software to ensure that the current battery testing and diagnostic procedures are used. Honda introduced a new policy to ensure that GR8 testers are updated promptly. The GR8 software must now be updated within 3 days of receiving notification from an iN message or other Honda communication. If an out-of-date version is used, any battery replacements may not be covered under warranty. GR8 UPDATE REQUIREMENTS ^ GR8 Battery Diagnostic Station: P/N MTRGR81100P ^ USB-to-mini-USB cable (this cable came with the GR8): Midtronics P/N A128 ^ Internet access ^ An IBM-compatible PC with Windows 95 operating system or higher (Windows 2000 or XP is preferred). To order the GR8 Diagnostic Station, or the USB-to-mini-USB cable, go to the Honda Tool and Equipment catalog on the iN (select Service > Service Bay > Tool and Equipment > Online Catalog), or call. SOFTWARE INFORMATION The current software version is listed online. Go to the iN (select Service > Service Bay > Diagnostic Tools Software Versions). To check the GR8 software version, click on: Language > Options > Info > Version WARRANTY CLAIM INFORMATION None. This service bulletin is for information only. GR8 UPDATE INSTRUCTIONS The update should take 5-10 minutes. Make sure that the update is not interrupted. If the update is interrupted, it could damage the GR8 and require you to send the GR8 to Midtronics for repair. This repair is not covered by warranty. 1. Make sure the GR8 is off and the SD card is removed. 2. Online, go to www.midtronics.com/home/clientlogin/clientlogin.aspx: 3. Enter your username and password, then click the Login button. Username: hondagr8 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Battery > Component Information > Technical Service Bulletins > Electrical - GR8 Battery Diagnostic Station Update Info. > Page 6716 Password: hondagr8 4. You should see an image of the GR8 tester. Click on the highlighted Update Software link under the image. 5. Fill in your dealer number, the service manager's name, and the GR8 serial number(s). The dealer name, the dealer address, and the dealer phone number are automatically filled in. Click SUBMIT REQUEST. 6. You should see the image of the GR8 tester again. Click on the highlighted Honda GR8 Software Update link. 7. A File Download - Security Warning screen appears. Select Run. 8. A file will be downloaded to your computer. After it is finished, an Internet Explorer - Security Warning screen appears. Select Run. NOTE: Depending on your network setup, you may see more warning screens than are shown here. *9. The Midtronics Update Wizard appears. Refer to SOFTWARE INFORMATION to find the current software version.* Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Battery > Component Information > Technical Service Bulletins > Electrical - GR8 Battery Diagnostic Station Update Info. > Page 6717 * NOTE: If the wrong software file appears or is not shown, click Change MUP File, and select the correct software version.* 10. Turn on the GR8, and follow the Update Wizard on-screen instructions. 11. When the update is complete, the Update Results screen appears, indicating the update was successful. Click Finish to close the Update Wizard. 12. Turn the GR8 off for 10 seconds. Reinstall the SD card, then turn the GR8 on, and confirm that the software is updated to the software version listed under SOFTWARE VERSION. 13. If an error message appears anytime during the update, follow the on-screen instructions, and try updating the GR8 again. If the error message still does not go away, or if you have any problems updating the GR8, call Midtronics. 14. If you have more than one GR8, repeat the update procedure for each unit. 15. Once all GR8s are updated, store the USB-to-mini-USB cable in a safe location for future updates. Disclaimer Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Battery > Component Information > Technical Service Bulletins > Electrical - GR8 Battery Diagnostic Station Update Info. > Page 6718 Battery: Technical Service Bulletins Electrical - ED-18 Battery Analyzer Update Info. 09-045 February 12, 2011 Applies To: ALL Honda Vehicles ED-18 Battery Analyzer Update Information (Supersedes 09-027, dated June 30, 2009, to revise the information marked by the asterisks) *REVISION SUMMARY Under SOFTWARE VERSION, the method to check the current software was updated.* INTRODUCTION The software for the ED-18 Battery Analyzer (or tester) is updated periodically to fix software bugs and enhance the tool's function. To help you update the ED-18 tester more quickly, American Honda no longer distributes CDs for the tester. You can now use the Midtronics ED-18 update wizard to download software and firmware to your ED-18 tester using a PC and the Internet. It is extremely important to use the latest ED-18 software to ensure that the current battery testing procedures are used. Honda introduced a new policy to ensure that ED-18 testers are updated promptly. The ED-18 software must now be updated within 3 days of receiving notification from an iN message or other Honda communication. If an out-of-date version is used, any battery replacements may not be covered under warranty. ED-18 UPDATE REQUIREMENTS ^ ED-18 Battery Analyzer: ED-18 Version 1: P/N INBED18LLH ED-18 Version 2: P/N INB17191840 ^ RS232 (25 pin to 9 pin) interface cable: P/N MTR130112A* ^ 7/64" hex wrench: P/N INBi7191270* *Both the R5232 interface cable and the hex wrench were included with the ED-18 update that was shipped to dealerships in November 2008. ^ A fully charged 12-volt automotive battery, any size ^ Internet access ^ An IBM-compatible PC: - Windows 95 operating system or higher (Windows 2000 or XP is preferred) - CD ROM - R5232 (9 pin) serial port, or an R5232 to USB Adapter (P/N MTRA164) (Some newer computers do not have an R5232 port. You will need to order the R5232 to USB adapter to update your ED-18 testers.) To order the ED-18 Battery Analyzer version 2, the interface cable, the R5232 to USB adapter, or the hex wrench, go to the Honda Tool and Equipment catalog on the iN (select Service > Service Bay > Tool and Equipment > Online Catalog), or call. NOTE: The ED-18 Battery Analyzer version 1 is no longer available for purchase. SOFTWARE VERSION Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Battery > Component Information > Technical Service Bulletins > Electrical - GR8 Battery Diagnostic Station Update Info. > Page 6719 *The current software version is listed online. Go to the iN (select Service > Service Bay > Diagnostic Tools Software Versions).* To check the ED-18 version 1 software, click on: Info > Version. The version number is located near the top of the version screen. To check the ED-18 version 2 software: ^ Turn on the tester, and read the version number on the screen. It should appear for about 3 seconds. ^ Or, you can click on: Language > Options > Info > Version. The version number is located near the top of the version screen. WARRANTY CLAIM INFORMATION None. This service bulletin is for information only. ED-18 UPDATE INSTRUCTIONS 1. Make sure the ED-18 is off, then detach the printer by using the hex wrench to remove the two screws at the bottom of the printer. Pull the printer straight out from the ED-18 to avoid damaging the connector terminals. 2. Connect the R8232 interface cable to the ED-18 where the printer was connected, then connect the interface cable to your PC. NOTE: If your computer doesn't have an R8232 serial port, use the R8232 to USB adapter. 3. Connect the ED-18 battery clamps to a fully charged 12-volt battery. 4. Online, go to Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Battery > Component Information > Technical Service Bulletins > Electrical - GR8 Battery Diagnostic Station Update Info. > Page 6720 5. Enter your username and password, then click the Login button. ^ For ED18 version 1: Username: hondaedv1 Password: hondaedv1 ^ For ED18 version 2: Username: hondaedv2 Password: hondaedv2 6. You should see an image of your ED-18 tester. Click on the highlighted Update Software link under the image. NOTE: The ED-18 tester version 2 software is shown. Version 1 is similar. 7. Fill in your dealer number, the service manager's name, and the ED-18 serial number(s). The dealer name, the dealer address, and the dealer phone number are automatically filled in. Click SUBMIT REQUEST. 8. You should see the image of your ED-18 tester again. Click on the highlighted Honda ED-18 V2 Software Update link. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Battery > Component Information > Technical Service Bulletins > Electrical - GR8 Battery Diagnostic Station Update Info. > Page 6721 9. A File Download - Security Warning screen appears. Select Run. 10. A file will be downloaded to your computer. After it is finished, an Internet Explorer - Security Warning screen appears. Select Run. NOTE: Depending on your network setup, you may see more warning screens than are shown here. 11. Turn on the ED-18. 12. Before using the Midtronics update utility, make sure your computer port settings are correct. Click on: My Computer > Control Panel > System > Hardware Tab > Device Manager. Or, you can click on: Windows Start button > Settings > Control Panel > System > Hardware Tab > Device Manager. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Battery > Component Information > Technical Service Bulletins > Electrical - GR8 Battery Diagnostic Station Update Info. > Page 6722 NOTE: If you are using an RS232 to USB adapter, make sure to plug it in before checking the port settings. Expand Ports, and check the communications port number. The communications port number should match the COMM number in the Midtronics update utility. If the numbers do not match, click on the arrows next to the COMM windows in the Midtronics update utility, and change the number to match the computer system's port number. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Battery > Component Information > Technical Service Bulletins > Electrical - GR8 Battery Diagnostic Station Update Info. > Page 6723 Make sure this communications port number matches the COMM number on the update. If it does not, change the number on the update. 13. Click on Start to begin the update, which takes about a minute. A progress bar appears. Wait until you get a message indicating the update was successful. NOTE: ^ If the clamps come off the battery, or the R8232 interface cable comes loose, turn the ED-18 off, then back on. When the logon screen appears on the ED-18, click on Start to restart the update. ^ If the error message Flash not erased appears, replace the AA batteries in the ED-18, and try the update again. 14. Click on OK on the ED-18 update. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Battery > Component Information > Technical Service Bulletins > Electrical - GR8 Battery Diagnostic Station Update Info. > Page 6724 15. Click on Quit on the ED-18 update. Make sure the message UPDATE COMPLETE appears on the ED-18 tester. 16. Turn the ED-18 tester off, then back on. 17. Confirm that the software on the ED-18 tester is updated to the software version listed under SOFTWARE VERSION. NOTE: If you have any problems updating the ED-18, call Midtronics at 866-592-8054. 18. Reinstall the printer. 19. If you have more than one ED-18, repeat the update procedure for each unit. 20. Once all ED-18s are updated, store the R5232 interface cable and the hex wrench in a safe location for future updates. Disclaimer Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Battery > Component Information > Technical Service Bulletins > Electrical - GR8 Battery Diagnostic Station Update Info. > Page 6725 Battery: Technical Service Bulletins Electrical - Battery Testing and Replacement Information 88-023 January 15, 2010 Applies To: ALL Battery Testing and Replacement (Supersedes 88-023, dated September 12, 2009, to revise the information marked by the black bars and asterisks) REVISION SUMMARY *^ Under WARRANTY CLAIM INFORMATION, battery claim Error Codes were added to some Warranty Requirements ^ The 2005 Model Year and Later battery coverage section was changed to 2005-10 Model Year Vehicles.* BACKGROUND Maintaining batteries in vehicles is an important part of ensuring a battery's operating life. American Honda recommends using the ED-18 and GR8 to check and maintain batteries. Refer to this bulletin for: ^ Information on when to use the ED-18 and the GR8. ^ Instructions on how to use the ED-18 and the GR8. ^ How to properly submit a battery warranty claim. REQUIRED TOOLS ^ GR8 Battery Diagnostic Station: P/N MTRGR81100P ^ ED-18 Battery Analyzer (Version 1 or 2): ED-18 Version 1: P/N INBEDi8LLH ED-18 Version 2: P/N INB17191840 NOTE: The ED-18 Battery Analyzer Version 1 is no longer available for purchase. Tool Requirements The GR8 and ED-18 software must be updated within 3 days of a new software update release. Refer to the applicable service bulletins for more information: ^ 09-060, GH8 Battery Diagnostic Station Update Information ^ 09-045, ED-18 Battery Analyzer Update Information Warranty Requirements The 10-digit test code must be included on a battery replacement claim. Refer to WARRANTY CLAIM INFORMATION. ORDERING INFORMATION To order the GR8 Battery Diagnostic Station or the ED-18-2 Battery Analyzer, go to the Honda Tool and Equipment catalog on the iN (select Service > Service Bay > Tool and Equipment Program > Online Catalog), or call. ED-18 AND GR8 USES New Arrivals, PDI, and Storage NOTE: Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Battery > Component Information > Technical Service Bulletins > Electrical - GR8 Battery Diagnostic Station Update Info. > Page 6726 For more information about documenting the scheduled battery checks, refer to Service Bulletin 89-003, Battery Maintenance at Dealers. ED-18 Battery Analyzer: ^ Check the condition of the battery and its state-of-charge: - When the vehicle arrives at your dealership - During the PDI - During scheduled battery maintenance while the vehicle is in storage - Before final delivery to the customer NOTE: Keep a printout of every battery test. Your warranty claim may be rejected unless you show that the battery was properly maintained. GR8 Battery Diagnostic Station: ^ Properly charge and diagnose the battery when indicated by the ED-18 ^ Smart, fast, and safe battery charging ^ Power supply mode maintains proper voltage during extended vehicle service, such as updating the PCM ^ Jump start mode supplies up to 250 amps Customer Scheduled Maintenance ED-18 Battery Analyzer: ^ Check the condition of the battery and its state-of-charge when a vehicle comes in for scheduled maintenance. GR8 Battery Diagnostic Station: ^ Properly charge and diagnose the battery when indicated by the ED-18 ^ Smart, fast, and safe battery charging ^ Power supply mode maintains proper voltage during extended vehicle service, such as updating the PCM ED-18 Battery Analyzer and GR8 Battery Diagnostic Station: ^ When the ED-18 or GR8 displays Replace Battery or Bad Cell Replace, it provides a 10-digit code that must be included with the warranty claim. See WARRANTY COVERAGE for more information. Used Vehicle Sale ED-18 Battery Analyzer: ^ Check the condition of the battery and its state-of-charge: - During vehicle inspection - During scheduled battery maintenance when the vehicle is in storage - Before final delivery to the customer GR8 Battery Diagnostic Station: ^ Properly charge and diagnose the battery when indicated by the ED-18 ^ Smart, fast, and safe battery charging ^ Power supply mode maintains proper voltage during extended vehicle service, such as updating the PCM ^ Jump start mode supplies up to 250 amps. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Battery > Component Information > Technical Service Bulletins > Electrical - GR8 Battery Diagnostic Station Update Info. > Page 6727 USING THE ED-18 BATTERY ANALYZER NOTE: ^ For set up, customizing, and other available features, refer to the ED-18 user's manual. ^ Make sure the setup has been completed, and the ED-18 updated to the most current software. The date and software version is very important for the proper result. Your warranty claim may not be paid if this information is wrong. See Tool Requirements under REQUIRED TOOLS for more information. ^ ED-18 version 2 is shown. Version 1 is similar. 1. Connect the leads to the battery's positive and negative terminals. 2. Use the arrow keys to select ENGLISH, then press Enter. 3. Use the arrow keys to select BATTERY, then press Enter. 4. Select your TECHNICIAN ID, then press Enter. After the summary of your technician ID appears, press Enter again. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Battery > Component Information > Technical Service Bulletins > Electrical - GR8 Battery Diagnostic Station Update Info. > Page 6728 5. Use the arrow or number keys to select the location of the battery, either OUT OF VEHICLE or IN VEHICLE, then press Enter. 6. Use the arrow or number keys to select FLOODED, then press Enter. NOTE: All Honda original equipment and replacement batteries are flooded types. If you select another battery type, your claim will not be covered by Honda's warranty. 7. Use the arrow or number keys to select the battery CCA value, then press Enter. You can find the CCA on the battery label on the top of the battery. If the battery hold-down plate is covering the label, loosen the plate and shift it out of the way to read the CCA. NOTE: Enter the correct cold cranking amps. If you enter the wrong number, the ED-18 analyzer result may be wrong, and the warranty claim may be rejected. 8. Measure the battery temperature by placing the analyzer's IR temperature sensor within 1 to 2 inches of the top or side of the battery. (The arrow on Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Battery > Component Information > Technical Service Bulletins > Electrical - GR8 Battery Diagnostic Station Update Info. > Page 6729 the top of the analyzer's housing indicates the sensor's location.) When the measured temperature on the display stabilizes, press Enter. 9. The analyzer displays the battery's current condition under RESULTS. The screen below shows one of four possible battery conditions, the battery's measured voltage, and the CCA. The screen includes a curved, two-section bar graph that represents the battery's condition. 10. Here are the four possible battery conditions: ^ Good Battery - This battery has at least 70% of its charge, 85% of its capacity, and requires no action. ^ GR8 Diagnostic Needed - The battery voltage is below 60% of its state of charge (SOC), and the condition of the battery is unknown. Use the GR8 to charge the battery and properly diagnose it. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Battery > Component Information > Technical Service Bulletins > Electrical - GR8 Battery Diagnostic Station Update Info. > Page 6730 ^ Replace Battery - The battery condition is poor. Replace it. ^ Bad Cell Replace - There is an internal problem with the battery. Replace it. 11. The screens toggle back and forth until you turn off the analyzer. To print the test results, press BACK. To return to the main menu, press CLEAR. NOTE: ^ If you need to submit a warranty claim, enter the 10-digit test code into the first two Diagnostic Trouble Code fields on the warranty claim. ^ If you enter the wrong CCA, or do not use the most current software version, your claim may be rejected. ^ The test results must state Replace Battery or Bad Cell Replace for a warranty battery replacement claim to be approved. USING THE GR8 DIAGNOSTIC MODE NOTE: ^ Use the GR8 diagnostic mode when the ED-18 indicates GR8 DIAGNOSTIC NEEDED. ^ For set up, customizing, and other available features, refer to the GR8 instruction manual; besides the one that comes with the GR8, the GR8 instruction manual is also available online. Select GENERAL PUBLICATIONS, select Tool Information, then select GR8-1100P Battery Diagnostic Station Instruction Manual from the list. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Battery > Component Information > Technical Service Bulletins > Electrical - GR8 Battery Diagnostic Station Update Info. > Page 6731 ^ Make sure the setup has been completed, and that the GR8 is updated to the most current software. The date and software version is very important for the proper result. Your warranty claim may not be paid if this information is wrong. See Tool Requirements under REQUIRED TOOLS for more information. 1. Plug in the GR8. 2. Connect the leads to the battery's positive and negative terminals. 3. Use the arrow keys to select ENGLISH, then press Enter. 4. Use the arrow keys to select DIAGNOSTIC, then press Enter. 5. Select your TECHNICIAN ID, then press Enter. After the summary of your technician ID appears, press Enter again. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Battery > Component Information > Technical Service Bulletins > Electrical - GR8 Battery Diagnostic Station Update Info. > Page 6732 6. Use the arrow keys to select either DEALER INVENTORY or CUSTOMER VEHICLE, then press Enter. 7. Use the arrow or number keys to select the location of the battery, either OUT OF VEHICLE or IN VEHICLE, then press Enter. 8. Use the arrow or number keys to select FLOODED, then press Enter. NOTE: All Honda original equipment and replacement batteries are flooded types. If you select another battery type, your claim will not be covered by Honda's warranty. 9. Use the arrow or number keys to select the battery CCA value, then press Enter. You can find the CCA on the battery label on the top of the battery. If the battery hold-down plate is covering the label, loosen the plate and shift it out of the way to read the CCA. NOTE: Enter the correct cold cranking amps. If you enter the wrong number, the GR8 result may be wrong, and the warranty claim may be rejected. 10. The screen changes to a progress bar while the GR8 tests the battery. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Battery > Component Information > Technical Service Bulletins > Electrical - GR8 Battery Diagnostic Station Update Info. > Page 6733 11. If the battery voltage is below 60% of its state of charge (SOC), or the condition of the battery is unknown, the GR8 automatically starts charging the battery and diagnosing it. NOTE: ^ The GR8 often states that charging and testing time is about 3 hours. Most actual charging and diagnostic times range between 15-25 minutes. ^ Battery charging times are affected by how the battery is discharged. If the battery discharged quickly (for example, the headlights were left on), the battery will recharge quickly. However, if the battery discharged slowly (for example, the battery was not checked for a very long time), it will take a lot longer to recharge it. 12. After the GR8 completes its diagnosis, it displays the battery's current condition. The screen shows one of three possible battery conditions, the battery's measured voltage, and the CCA. The screen includes a curved, two-section bar graph that represents the battery's condition. 13. Here are the three possible battery conditions: ^ Good Battery - This battery has at least 70% of its charge and requires no action. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Battery > Component Information > Technical Service Bulletins > Electrical - GR8 Battery Diagnostic Station Update Info. > Page 6734 ^ Replace Battery - The battery condition is poor. Replace it. ^ Bad Cell Replace - There is a problem with the battery. Replace it. 14. The screens toggle back and forth until you turn off the tester. To print the test results, press BACK. To return to the main menu, press CLEAR. NOTE: ^ If you need to submit a warranty claim, enter the 10-digit test code into the first two Diagnostic Trouble Code fields on the warranty claim. ^ If you enter the wrong CCA, or do not use the most current software version, your claim may be rejected. ^ The test results must state Replace Battery or Bad Cell Replace for a warranty battery replacement claim to be approved. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Battery > Component Information > Technical Service Bulletins > Electrical - GR8 Battery Diagnostic Station Update Info. > Page 6735 USING THE GR8 DIAGNOSTIC STATION - ED-18 BATTERY TEST FUNCTION NOTE: ^ The ED-18 battery test function in the GR8 should be used only when your ED-18 is out of service. ^ For set up, customizing, and other available features, refer to the GR8 instruction manual besides the one that comes with the GR8, the GR8 instruction manual is also available online. Select GENERAL PUBLICATIONS, select Tool Information, then select Honda GR8-1100P Battery Diagnostic Station Instruction Manual from the list. ^ Make sure the setup has been completed, and the GR8 updated to the most current software. The date and software version is very important for the proper result. Your warranty claim may not be paid if this information is wrong. See Tool Requirements under REQUIRED TOOLS for more information. 1. Plug in the GR8. 2. Connect the leads to the battery's positive and negative terminals. 3. Use the arrow keys to select ENGLISH, then press Enter. 4. Use the arrow keys to select OPTIONS, then press Enter. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Battery > Component Information > Technical Service Bulletins > Electrical - GR8 Battery Diagnostic Station Update Info. > Page 6736 5. Use the arrow keys to select ED-18 Test, then press Enter. 6. Select your TECHNICIAN ID, then press Enter. After the summary of your technician ID appears, press Enter again. 7. Use the arrow keys to select either DEALER INVENTORY or CUSTOMER VEHICLE, then press Enter. 8. Use the arrow or number keys to select the location of the battery, either OUT OF VEHICLE or IN VEHICLE, then press Enter. 9. Use the arrow or number keys to select the FLOODED, then press Enter. NOTE: All Honda original equipment and replacement batteries are flooded types. If you select another battery type, your claim will not be covered by Honda's warranty. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Battery > Component Information > Technical Service Bulletins > Electrical - GR8 Battery Diagnostic Station Update Info. > Page 6737 10. Use the arrow or number keys to select the battery CCA value, then press Enter. You can find the CCA on the battery label on the top of the battery. If the battery hold-down plate is covering the label, loosen the plate and shift it out of the way to read the CCA. NOTE: Enter the correct cold cranking amps. If you enter the wrong number, the battery test result may be wrong, and the warranty claim may be rejected. 11. The screen changes to a progress bar while the GR8 tests the battery. 12. If the battery voltage is below 60% of its state of charge (SOC), or the condition of the battery is unknown, the GR8 automatically changes to its diagnostic feature. A screen stating CHARGING RECOMMENDED. DO YOU WANT TO CONTINUE?" appears. Select Yes. After the battery is charged and diagnosed, go to step 13. NOTE: ^ The GR8 often states that charging and testing time is about 3 hours. Most actual charging and diagnostic times range between 15-25 minutes. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Battery > Component Information > Technical Service Bulletins > Electrical - GR8 Battery Diagnostic Station Update Info. > Page 6738 ^ Battery charging times are affected by how the battery is discharged. If the battery discharged quickly (for example, the headlights were left on), the battery will recharge quickly. However, if the battery discharged slowly (for example, the battery was not checked for a very long time), it will take a lot longer to recharge it. 13. The tester displays the battery's current condition. The screen shows one of three possible battery conditions, the battery's measured voltage, and the CCA. The screen includes a curved, two-section bar graph that represents the battery's condition. 14. Here are the three possible battery conditions: ^ Good Battery - This battery has at least 70 percent of its charge and requires no action. ^ Replace Battery - The battery condition is poor. Replace it. ^ Bad Cell Replace - There is a problem with the battery. Replace it. 15. The screens toggle back and forth until you turn off the tester. To print the test results, press BACK. To return to the main menu, press CLEAR. NOTE: ^ If you need to submit a warranty claim, enter the 10-digit test code into the first two Diagnostic Trouble Code fields on the warranty claim. ^ If you enter the wrong CCA, or do not use the most current software version, your claim may be rejected. ^ The test results must state Replace Battery or Bad Cell Replace for a warranty battery replacement claim to be approved. WARRANTY CLAIM INFORMATION Battery Replacement - Original Equipment Battery Limited Warranty (Factory-Installed Battery or AHM Parts Battery) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Battery > Component Information > Technical Service Bulletins > Electrical - GR8 Battery Diagnostic Station Update Info. > Page 6739 Operation Number: 710100 Flat Rate Time: 0.3 hour Symptom Code: 07002 DTC: Enter the 10-digit test code into the first two Diagnostic Trouble Code fields in the warranty claim. Warranty Requirements ^ Only batteries that are Original Equipment (factory-installed) or supplied by AHM Parts are covered by the Original Equipment Battery Limited Warranty. ^ No battery warranty claim will be accepted without the 10-digit test code from the ED-18 Battery Analyzer or the GR8 Battery Diagnostic Station. ^ Enter the 10-digit test code into the Warranty Claim DTC fields one and two. ^ The battery tester print-out stating Replace Battery or Bad Cell Replace must be attached to the related repair order or the warranty claim will not be approved. ^ All batteries replaced under warranty must have a warranty claim tag attached to it. ^ If you have a battery under warranty that needs replacement for a non-electrical defect (like a cracked case) and the battery tester does not display Replace Battery or Bad Cell Replace, contact your District Parts and Service Manager (DPSM) for help. *^ The battery claim will be returned to your dealership unpaid with an Error Code of 2081 if the tester printout does not state Replace Battery or Bad Cell Replace. ^ A battery claim will be returned to the dealership unpaid with an Error Code of 2082 if the technician entered the CCA (from the ED-18 Rating field or the GR8 Test Info field) that does not match the factory-installed battery or the AHM Parts replacement battery CCA. Make sure the CCA matches the model and model year on the iN (Interactive Network). Go to Service > Service Library > Claims Reference Guide > Coverage Tables > Battery Warranty. ^ The ED-18 and GR8 must have the most current software version. Honda policy states that you must update your tools within 3 days of being notified that an update is available. A battery claim will be returned to the dealership unpaid with an Error Code of 2083 if a repair order (RO) date is Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Battery > Component Information > Technical Service Bulletins > Electrical - GR8 Battery Diagnostic Station Update Info. > Page 6740 7 days or later after the software activation date for the latest tester software. See REQUIRED TOOLS for more information about the current software version and how to update your tools. You can also check the software version active dates on the iN. Go to Service > Service Library > Claims Reference Guide > Coverage Tables > Battery Warranty. ^ All Honda 12-volt batteries are lead-acid (flooded type). No other battery types are accepted. If you try to submit a claim with a battery that was not tested as flooded, the claim will be returned to your dealership unpaid with an Error Code of 2084. See step 6 of USING THE ED-18 BATTERY TESTER or step 9 of USING THE GR8 DIAGNOSTIC STATION - ED-18 BATTERY TEST FUNCTION for how to test the battery.* ED-18 and GR8 battery test codes are used for product research and warranty validation. Some of the information gathered is: - Tool type - Software version - Test date - Test results: ^ Battery voltage ^ CCA results ^ Battery condition ^ Battery temperature - Tech-entered information: ^ Battery CCA ^ Battery type Unsold New Vehicles The dealer is responsible for testing and charging batteries when the vehicle first arrives at the dealership and while in dealer inventory. Testing and charging to maintain the battery in a new and unsold vehicle cannot be claimed under warranty. If you let a good battery sit discharged, and it is damaged from poor maintenance, this is not a defect, and the replacement is not covered by warranty. If your dealership receives a new vehicle (less than 2 weeks since delivery) with a defective battery (your ED-18 or GR8 states Replace Battery or Bad Cell, plus the 10-digit code), you can file a warranty claim. You must show the printout from the ED18 or GR8 and the vehicle delivery document (bill of lading) to your DPSM and request their approval of claim error 3050, No Warranty - In Stock Battery. You are required to test the battery during the PDI and at final delivery. Record the 10-digit test code created by the ED-i8 or GR8 in the applicable places of the Service History booklet, and place a printout of the tester results in the vehicle file. See RECORD KEEPING in Service Bulletin 89-003, Battery Maintenance at Dealers, for more information. Acceptable printouts must have this information: ^ A test date matching the PDI or final delivery date ^ The correct CCA value for the battery tested ^ A Good Battery test result ^ VIN (written by tech on printout) Customer-Owned Vehicles From 0 to 90 Days Warranty claim error code 3055 was created for battery replacement claims within 90 days of delivery to the customer. It can be cleared only by a DPSM. For your DPSM to override warranty claim error code 3055, you need to provide this documentation: ^ The initial PDI battery test printout that matches the PDI date or the new arrival battery test printout and the vehicle delivery document (bill of lading), lists the correct CCA rating, and shows the battery condition as Good Battery. ^ The Final Inspection that matches the date of the vehicle delivery, lists the correct CCA rating, and shows the battery condition as Good Battery. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Battery > Component Information > Technical Service Bulletins > Electrical - GR8 Battery Diagnostic Station Update Info. > Page 6741 ^ The latest battery test that shows Replace Battery or Bad Cell Replace. Use the 10-digit code from this test when submitting the warranty claim. Customer-Owned Vehicles From 91 Days to 3 Years All battery warranty claims need an ED-18 or GR8 test code included under the DTC (Diagnostic Trouble Code) field. Any claims submitted without a code will be rejected, and test codes are audited for accuracy. Attach the ED-18 or GR8 tester printout that states Replace Battery or Bad Cell - Replace. If your claim is rejected with the claim error codes 2080 or 2081, refer to these code explanations: ^ 2080 - Battery test code required. Enter the 10-digit code from the ED-18 or GR8 in the DTC field and resubmit. ^ 2081 - Good battery or invalid battery code. This code is created when you submit a 10-digit code that indicates a Good Battery, Charge & Retest, or an invalid code was entered. Refer to the owner's manual or current Service Operations Manual for warranty coverage. Each defective battery replaced under warranty must have a warranty claim tag securely attached to it. If you need to replace a battery because of a non-electrical problem (for example, the case is cracked) but the ED-18 or GR8 reads that the battery is good, contact your DPSM for help. Warranty Coverage Enter the warranty claim information listed, and the full dealer net amount. The parts and labor reimbursement is calculated according to the following tables after you submit the warranty claim. 2005-10 Model Year Vehicles *Batteries in 2005-10 model year vehicles are covered in full for parts and labor with no mileage limit for 36 months.* 2004 Model Year and Earlier See section 2.18 of the Service Operations Manual for more information. Parts Warranty - Replacement Battery Limited Warranty (Customer paid at a Honda dealership for an AHM Parts battery) Operation Number: 000005 Flat Rate Time: 0.3 hour Defect Code: 862 Symptom Code: 07002 DTC: Enter the 10-digit test code into the first two Diagnostic Trouble Code fields in the warranty claim. Refer to the Warranty Requirements under Battery Replacement - Original Equipment Battery Limited Warranty. Warranty Coverage Enter and submit a parts warranty claim with the information listed and the full dealer net amount. The parts and labor reimbursement is calculated according to the schedule below after the warranty claim is submitted. Replacement Batteries Sold On or After November 1, 2004 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Battery > Component Information > Technical Service Bulletins > Electrical - GR8 Battery Diagnostic Station Update Info. > Page 6742 Batteries are covered for 100 months, with full coverage for the first 36 months in service and prorated between the 37th and 100th month of service as listed in the table. Replacement Batteries Sold Between February 1, 2000, and October 31, 2004 See Section 2.18 of the Service Operations Manual for more information. Disclaimer Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Mitsubishi Alternator Alternator: Specifications Mitsubishi Alternator Output Amperage, Amps ..................................................................................................................... ............................................................................... 70 Coil Resistance, Ohms @ 68°F ...................... ............................................................................................................................................................. 3.4-3.8 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Mitsubishi Alternator > Page 6748 Alternator: Specifications Nippondenso Alternator Output Amperage, Amps ..................................................................................................................... ............................................................................... 70 Coil Resistance, Ohms @ 68°F ...................... .............................................................................................................................................................. ..... 2.3 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 6749 Alternator: Locations Left Side Of Engine Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions Alternator: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6752 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6753 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6754 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6755 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6756 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6757 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6758 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6759 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6760 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6761 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6762 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6763 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6764 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6765 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6766 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6767 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6768 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6769 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6770 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6771 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6772 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6773 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6774 Alternator: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6775 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6776 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6777 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6778 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6779 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6780 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6781 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6782 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6783 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6784 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6785 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6786 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6787 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6788 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6789 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6790 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6791 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6792 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6793 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6794 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6795 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6796 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6797 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6798 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6799 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6800 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6801 Alternator: Electrical Diagrams Charging System- Mitsubishi Type (Part 1 Of 2) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6802 Charging System- Mitsubishi Type (Part 2 Of 2) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6803 Charging System- Nippondenso Type (Part 1 Of 2) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6804 Charging System- Nippondenso Type (Part 2 Of 2) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Locations Clutch Switch: Locations Behind Left Side Of Dash Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Testing and Inspection > Hitachi Starters Clutch Switch: Testing and Inspection Hitachi Starters 1. Remove instrument panel lower cover and left knee bolster. 2. Disconnect connector from switch. 3. With clutch pedal released, check continuity between both terminals. No continuity should be found. If continuity is found, replace or adjust switch as necessary. 4. With clutch pedal depressed, check continuity between both terminals. Continuity should be found. If no continuity is found, replace or adjust switch as necessary. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Testing and Inspection > Hitachi Starters > Page 6811 Clutch Switch: Testing and Inspection Mitsuba Starters 1. Remove instrument panel lower cover and left knee bolster. 2. Disconnect connector from switch. 3. With clutch pedal released, check continuity between both terminals. No continuity should be found. If continuity is found, replace or adjust switch as necessary. 4. With clutch pedal depressed, check continuity between both terminals. Continuity should be found. If no continuity is found, replace or adjust switch as necessary. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Testing and Inspection > Hitachi Starters > Page 6812 Clutch Switch: Testing and Inspection Nippondenso Starters 1. Remove instrument panel lower cover and left knee bolster. 2. Disconnect connector from switch. 3. With clutch pedal released, check continuity between both terminals. No continuity should be found. If continuity is found, replace or adjust switch as necessary. 4. With clutch pedal depressed, check continuity between both terminals. Continuity should be found. If no continuity is found, replace or adjust switch as necessary. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch Ignition Lock: Technical Service Bulletins Starting System - Unable To Key In Ignition Switch Can't Turn Ignition Switch? Check for Locked Steering Got a service customer complaining he or she can't turn the ignition switch to start the engine? The reason could just be the steering column lock pin is engaged with the front wheels turned. Here's what typically happens: Some folks use the steering wheel to help support themselves while climbing in or out of the vehicle. This is very common among elderly or disabled drivers. Doing this turns the front wheels, which twists the tires against the ground. The twisted tires apply torque to the steering column. With the ignition switch in LOCK (0), the steering column lock pin is engaged. But the applied torque on the steering column binds the lock pin, making it tough to turn the ignition switch. The ignition switch won't turn to ON (II) if the lock pin isn't disengaged from the steering column. Tell your customer there's nothing wrong with the ignition switch itself. All he or she needs to do is turn the steering wheel from side to side while turning the switch. This usually releases the lock pin so the engine can be started. In some cases, though, your customer may need to give a good tug on the wheel. This could easily happen when parking on a hill and the wheels are turned sharply before the engine is shut off. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch > Page 6817 Ignition Lock: Technical Service Bulletins Tools - Exacta Code Key Cutter BULLETIN NO. 88-012 ISSUE DATE AUG 8, 1994 MODEL ALL APPLICABLE TO ALL FILE UNDER SPECIAL TOOLS Exacta Code Key Cutter (Supersedes 88-012, "Code Key Cutter," dated March 18, 1988) The Exacta Code Key Cutter, Manufactured by IIco Unican Co. is available from American Honda to meet your minimum key cutting requirements. For use and care, follow the manufacturer's instructions included with the Code Key Cutter Base Kit. Features of the Exacta Code Key Cutter: PARTS INFORMATION Code Key Cutter Base Kit: H/C 2942548, TIN 07JAB-001000A 45-Degree Code Key Cutter Accessory Kit: H/C 2942886, TIN 07JAB-001002A 47-Degree Code Key Cutter Accessory Kit: H/C 2942555, T/N 07JAB-001001A 1994 Passport Code Key Cutter Accessory Kit: H/C 4447587, P/N 07RAB-001030A Note For Code Key Cutter Accessory Kit contents, and model application, refer to the Application Chart. ORDERING INFORMATION ^ The Exacta Code Key Cutter Base Kit and Accessory Kits are available from American Honda using your normal parts ordering procedures. The kits will be shipped to you directly from the manufacturer. If you need to order individual replacement parts, or if items are missing from your shipment, contact IIco Unican Co. at (800) 334-1381, and ask for the American Honda sales representative. Refer to the Application Chart for IIco Unican part numbers. ^ Key blanks do not come with the kits ordered from American Honda; refer to your Parts Reference Guide for key blanks. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch > Page 6818 ^ If you are using a Curtis Key Cutter and need parts or information, contact: Curtis Industries, Inc. 34999 Curtis Blvd., Eastlake, OH 44094-4899 (216) 951-2400. APPLICATION CHART Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > Page 6819 Ignition Lock: Service and Repair 1. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. 2. Disconnect battery ground cable. 3. Remove instrument panel lower cover and knee bolster. 4. Disconnect ignition switch connectors, then remove steering column covers. 5. Remove column holder mounting bolts and nuts, then lower steering column assembly. 6. Center punch each of two shear screw heads, then use suitable drill and drill bit to remove screw heads and the switch. 7. Install new switch without ignition key inserted. 8. Hand tighten shear screws, then insert ignition key and check for proper operation of wheel lock. 9. Tighten shear screws until hex heads twist off. 10. Raise steering column assembly, then install column holder mounting bolts and nuts. 11. Reconnect switch connectors. 12. Position switch wiring and install steering column covers. 13. Install dashboard lower cover and knee bolster. 14. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch Ignition Switch Lock Cylinder: Technical Service Bulletins Starting System - Unable To Key In Ignition Switch Can't Turn Ignition Switch? Check for Locked Steering Got a service customer complaining he or she can't turn the ignition switch to start the engine? The reason could just be the steering column lock pin is engaged with the front wheels turned. Here's what typically happens: Some folks use the steering wheel to help support themselves while climbing in or out of the vehicle. This is very common among elderly or disabled drivers. Doing this turns the front wheels, which twists the tires against the ground. The twisted tires apply torque to the steering column. With the ignition switch in LOCK (0), the steering column lock pin is engaged. But the applied torque on the steering column binds the lock pin, making it tough to turn the ignition switch. The ignition switch won't turn to ON (II) if the lock pin isn't disengaged from the steering column. Tell your customer there's nothing wrong with the ignition switch itself. All he or she needs to do is turn the steering wheel from side to side while turning the switch. This usually releases the lock pin so the engine can be started. In some cases, though, your customer may need to give a good tug on the wheel. This could easily happen when parking on a hill and the wheels are turned sharply before the engine is shut off. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch Key: Technical Service Bulletins Starting System - Unable To Key In Ignition Switch Can't Turn Ignition Switch? Check for Locked Steering Got a service customer complaining he or she can't turn the ignition switch to start the engine? The reason could just be the steering column lock pin is engaged with the front wheels turned. Here's what typically happens: Some folks use the steering wheel to help support themselves while climbing in or out of the vehicle. This is very common among elderly or disabled drivers. Doing this turns the front wheels, which twists the tires against the ground. The twisted tires apply torque to the steering column. With the ignition switch in LOCK (0), the steering column lock pin is engaged. But the applied torque on the steering column binds the lock pin, making it tough to turn the ignition switch. The ignition switch won't turn to ON (II) if the lock pin isn't disengaged from the steering column. Tell your customer there's nothing wrong with the ignition switch itself. All he or she needs to do is turn the steering wheel from side to side while turning the switch. This usually releases the lock pin so the engine can be started. In some cases, though, your customer may need to give a good tug on the wheel. This could easily happen when parking on a hill and the wheels are turned sharply before the engine is shut off. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Hitachi Starter Motor: Specifications Hitachi Brush Spring Tension, Oz. .................................................................................................................. ............................................................................ 56.3 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Hitachi > Page 6833 Starter Motor: Specifications 1.0 KW Power Rating Power Rating, kW ................................................................................................................................ ................................................................................ 1 Brush Spring Tension, Oz. .............................. .............................................................................................................................................................. 65-83 Maximum Load, Amps ............................................................................................................... ...................................................................................... 400 Normal Engine Cranking, RPM ............. .............................................................................................................................................................. ............ 100 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Hitachi > Page 6834 Starter Motor: Specifications 1.2 KW Power Rating Power Rating, kW ................................................................................................................................ ............................................................................. 1.2 Brush Spring Tension, Oz. .............................. .............................................................................................................................................................. 65-83 Maximum Load, Amps ............................................................................................................... ...................................................................................... 400 Normal Engine Cranking, RPM ............. .............................................................................................................................................................. ............ 100 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Hitachi > Page 6835 Starter Motor: Specifications 1.4 KW Power Rating Power Rating, kW ................................................................................................................................ ............................................................................. 1.4 Brush Spring Tension, Oz. .............................. .............................................................................................................................................................. 56-63 Maximum Load, Amps ............................................................................................................... ...................................................................................... 400 Normal Engine Cranking, RPM ............. .............................................................................................................................................................. ............ 100 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 6836 Starter Motor: Locations Right Side Of Engine Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing and Inspection > Hitachi Starters Starter Motor: Testing and Inspection Hitachi Starters Ensure air temperature is between 59-100°F before testing. 1. Connect suitable battery-starter tester according to manufacturer's instructions. Fig. 4 Distributor 2-P Connector Location 2. Disconnect 2-P connector from distributor, Fig. 4. 3. Press clutch pedal to floor and turn ignition switch to Start position. If starter does not crank engine, check battery condition, battery positive wire, ground and wire connections for looseness or corrosion. 4. If starter still does not crank engine, bypass ignition switch circuit as follows: a. Disconnect black/white wire from solenoid terminal on starter. b. Connect jumper wire from battery positive terminal to solenoid terminal. c. If starter cranks engine, check for open in black/white wire circuit between starter and ignition switch. If circuit is satisfactory, check connectors and ignition switch. d. On models with automatic transaxle, check neutral safety switch and connector. e. On models with manual transaxle, check starter relay, clutch interlock switch and connectors. 5. If starter still does not crank engine, remove and diagnose for internal problems. 6. Check voltage and current draw, then compare as follows: a. Cranking voltage should be no less than 8 volts and current draw should not be more than 400 amps. b. Engine speed when cranking should be above 100 RPM. If engine speed is not at least 100 RPM, check for loose battery or starter terminals, worn starter brushes, open circuit in commuter segments, dirty or damaged helical spline or drive gear, and defective drive gear overrunning clutch. 7. Check for starter disengagement as follows: a. On models with manual transaxle, press clutch pedal to floor. b. Turn ignition switch to Start and release to Run. c. If starter drive gear hangs up on flywheel or flex plate, check solenoid plunger and switch for malfunction or drive gear assembly for dirty or damaged overrunning clutch. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing and Inspection > Hitachi Starters > Page 6839 Starter Motor: Testing and Inspection Mistuba Starters Ensure air temperature is between 59-100°F before testing. 1. Connect suitable battery-starter tester according to manufacturers instructions. 2. Disconnect 2-P connector from distributor. 3. On models with manual transaxle, press clutch pedal to floor. 4. Turn ignition switch to Start position. If starter does not crank engine, check battery condition, battery positive wire, ground and wire connections for looseness or corrosion. 5. If starter still does not crank engine, bypass ignition switch circuit as follows: a. Disconnect black/white wire from solenoid terminal on starter. b. Connect a jumper wire from battery positive terminal to solenoid terminal. c. If starter cranks engine, check for an open in black/white wire circuit between starter and ignition switch. If circuit is satisfactory, check connectors and ignition switch. d. On models with automatic transaxle, check neutral safety switch and connector. e. On models with manual transaxle, check starter relay, clutch interlock switch and connectors. 6. If starter still does not crank engine, remove and diagnose for internal problems. 7. Check voltage and current draw. Cranking voltage on all starters should be no less than 8 volts and current draw should be no more than 400 amps. 8. Check for starter disengagement as follows: a. On models with manual transaxle, press clutch pedal to floor. b. Turn ignition switch to Start and release to Run. c. If starter drive gear hangs up on flywheel or flex plate, check solenoid plunger and switch for malfunction or drive gear assembly for dirty or damaged overrunning clutch. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing and Inspection > Hitachi Starters > Page 6840 Starter Motor: Testing and Inspection Nippondenso Starters Ensure air temperature is between 59-100°F before testing. 1. Connect a suitable battery-starter tester according to manufacturers instructions. Fig. 12 Distributor 2-P Connector Location 2. Disconnect 2-P connector from distributor, Fig. 12.. 3. On models with manual transaxle, press clutch pedal to floor. 4. Turn ignition switch to Start position. If starter does not crank engine, check battery condition, battery positive wire, ground and wire connections for looseness or corrosion. 5. If starter still does not crank engine, bypass ignition switch circuit as follows: a. Disconnect black/white wire from solenoid terminal on starter. b. Connect a jumper wire from battery positive terminal to solenoid terminal. c. If starter cranks engine, check for an open in black/white wire circuit between starter and ignition switch. If circuit is satisfactory, check connectors and ignition switch. d. On models with automatic transaxle, check neutral safety switch and connector. e. On models with manual transaxle, check starter relay, clutch interlock switch and connectors. 6. If starter still does not crank engine, remove and diagnose for internal problems. 7. Check voltage and current draw. Cranking voltage on all starters should be no less than 8 volts and current draw should be no more than 400 amps. 8. Engine speed when cranking on both reduction gear and direct drive starters should be above 100 RPM. If engine speed is not at least 100 RPM, check for loose battery or starter terminals, worn starter brushes, open circuit in commuter segments, dirty or damaged helical spline or drive gear, and defective drive gear overrunning clutch. 9. Check for starter disengagement as follows: a. On models with manual transaxle, press clutch pedal to floor. b. Turn ignition switch to Start and release to Run. c. If starter drive gear hangs up on flywheel or flex plate, check solenoid plunger and switch for malfunction or drive gear assembly for dirty or damaged overrunning clutch. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing and Inspection > Page 6841 Starter Motor: Service and Repair 1. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. 2. Disconnect battery ground cable, then wait at least three minutes before continuing procedure. 3. Disconnect positive battery cable. 4. On all models, disconnect all electrical leads at starter. 5. Remove starter mounting bolts, then the starter. 6. Reverse procedure to install, torque starter mounting bolts to 32 ft. lbs. 7. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations Starter Relay: Locations Behind Left Side Of Dash Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Testing and Inspection > Hitachi Starters Starter Relay: Testing and Inspection Hitachi Starters 1. Remove and disconnect starter relay. Fig. 5 Starter Relay Terminal Locations 2. Apply battery voltage to C and D terminals of relay, Fig. 5. 3. Check continuity between A and B terminals of relay. Continuity should exist. 4. Disconnect battery voltage. There should be no continuity between A and B terminals of relay. 5. If relay does not operate as specified, replace relay. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Testing and Inspection > Hitachi Starters > Page 6847 Starter Relay: Testing and Inspection Mitsuba Starters 1. Remove and disconnect starter relay. Fig. 10 Starter Relay Terminal Locations 2. Apply battery voltage to C and D terminals of relay, Fig. 10. 3. Check continuity between A and B terminals of relay. Continuity should exist. 4. Disconnect battery voltage. There should be no continuity between A and B terminals of relay. 5. If relay does not operate as specified, replace relay. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Testing and Inspection > Hitachi Starters > Page 6848 Starter Relay: Testing and Inspection Nippondenso Starters 1. Remove and disconnect starter relay. Fig. 13 Starter Motor Terminal Locations 2. Apply battery voltage to C and D terminals of relay, Fig. 13. 3. Check continuity between A and B terminals of relay. Continuity should exist. 4. Disconnect battery voltage. There should be no continuity between A and B terminals of relay. 5. If relay does not operate as specified, replace relay. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Testing and Inspection > Hitachi Starters Starter Solenoid: Testing and Inspection Hitachi Starters Fig. 6 Starter Motor Terminal Locations 1. Check hold in coil for continuity between S terminal and ground, Fig. 6. Continuity should exist. 2. Check pull in coil for continuity between S and M terminals. Continuity should exist. 3. If solenoid does not operate as specified, replace solenoid. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Testing and Inspection > Hitachi Starters > Page 6853 Starter Solenoid: Testing and Inspection Mitsuba Starters Fig. 11 Starter Motor Terminal Locations 1. Check hold in coil for continuity between S terminal and ground, Fig. 1. Continuity should exist. 2. Check pull in coil for continuity between S and M terminals. Continuity should exist. 3. If solenoid does not operate as specified, replace solenoid. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Testing and Inspection > Hitachi Starters > Page 6854 Starter Solenoid: Testing and Inspection Nippondenso Starters Fig. 14 Starter Relay Terminal Locations 1. Check hold in coil for continuity between S terminal and ground as shown in Fig. 14. Continuity should exist. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Under-Dash Fuse/Relay Box Fuse: Locations Under-Dash Fuse/Relay Box Photo Behind Left Side Of Dash Under Dash Fuse/Relay Box Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Under-Dash Fuse/Relay Box > Page 6860 Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Under-Dash Fuse/Relay Box > Page 6861 Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 2 Of 3) Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 3 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Under-Dash Fuse/Relay Box > Page 6862 Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 3 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Under-Dash Fuse/Relay Box > Page 6863 Fuse: Locations Under-Hood Fuse/Relay Box Right Rear Corner Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Under-Dash Fuse/Relay Box > Page 6864 Fuse: Locations Under-Hood ABS Fuse/Relay Box Fuse/Relay Information-Under-hood ABS Fuse/Relay Box Right Side Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Under Dash Fuse/Relay Box Fuse: Application and ID Under Dash Fuse/Relay Box Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 1 Of 3) Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Under Dash Fuse/Relay Box > Page 6867 Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 2 Of 3) Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 3 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Under Dash Fuse/Relay Box > Page 6868 Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 3 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Under Dash Fuse/Relay Box > Page 6869 Fuse: Application and ID Under-Dash Fuse/Relay Box Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 1 Of 3) Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Under Dash Fuse/Relay Box > Page 6870 Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 2 Of 3) Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 3 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Under Dash Fuse/Relay Box > Page 6871 Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 3 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Under Dash Fuse/Relay Box > Page 6872 Fuse: Application and ID Under-Hood ABS Fuse/Relay Box Fuse/Relay Information-Under-hood ABS Fuse/Relay Box Fuse/Relay Information-Under-hood ABS Fuse/Relay Box Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Under Dash Fuse/Relay Box > Page 6873 Fuse: Application and ID Under-Hood Fuse/Relay Box Fuse/Relay Information-Under-hood Fuse/Relay Box (Part 1 Of 2) Fuse/Relay Information-Under-hood Fuse/Relay Box (Part 1 Of 2) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Under Dash Fuse/Relay Box > Page 6874 Fuse/Relay Information-Under-hood Fuse/Relay Box (Part 2 Of 2) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > SRS Fuse Block Fuse Block: Locations SRS Fuse Block Behind Left Side Of Dash Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > SRS Fuse Block > Page 6879 Fuse Block: Locations Under-Dash Fuse/Relay Box Behind Left Side Of Dash Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > SRS Fuse Block > Page 6880 Fuse Block: Locations Under-Hood ABS Fuse/Relay Box Right Side Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > SRS Fuse Block > Page 6881 Fuse Block: Locations Under-Hood Fuse/Relay Box Right Rear Corner Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Under-Hood ABS Fuse/Relay Box Fuse Block: Application and ID Under-Hood ABS Fuse/Relay Box Fuse/Relay Information-Under-hood ABS Fuse/Relay Box Fuse/Relay Information-Under-hood ABS Fuse/Relay Box Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Under-Hood ABS Fuse/Relay Box > Page 6884 Fuse Block: Application and ID Under-Dash Fuse/Relay Box Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 1 Of 3) Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Under-Hood ABS Fuse/Relay Box > Page 6885 Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 2 Of 3) Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 3 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Under-Hood ABS Fuse/Relay Box > Page 6886 Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 3 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Under-Hood ABS Fuse/Relay Box > Page 6887 Fuse Block: Application and ID Under-Hood Fuse/Relay Box Fuse/Relay Information-Under-hood Fuse/Relay Box (Part 1 Of 2) Fuse/Relay Information-Under-hood Fuse/Relay Box (Part 1 Of 2) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Under-Hood ABS Fuse/Relay Box > Page 6888 Fuse/Relay Information-Under-hood Fuse/Relay Box (Part 2 Of 2) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Locations > Photo 23 Multiple Junction Connector: Locations Photo 23 Left Rear Corner Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Locations > Photo 23 > Page 6893 Multiple Junction Connector: Locations Photo 54 Left Kick Panel Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Locations > Photo 23 > Page 6894 Multiple Junction Connector: Locations Photo 63 Behind Left Side Of Dash Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Electrical Load Detector (ELD) Unit Relay Box: Locations Electrical Load Detector (ELD) Unit Bottom Of Under-hood Fuse/Relay Box Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Electrical Load Detector (ELD) Unit > Page 6900 Relay Box: Locations Under-Dash Fuse/Relay Box Photo Behind Left Side Of Dash Under Dash Fuse/Relay Box Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Electrical Load Detector (ELD) Unit > Page 6901 Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Electrical Load Detector (ELD) Unit > Page 6902 Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 2 Of 3) Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 3 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Electrical Load Detector (ELD) Unit > Page 6903 Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 3 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Electrical Load Detector (ELD) Unit > Page 6904 Relay Box: Locations Under-Hood ABS Fuse/Relay Box Photo Right Side Of Engine Compartment Fuse/Relay Information-Under-hood ABS Fuse/Relay Box Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Electrical Load Detector (ELD) Unit > Page 6905 Fuse/Relay Information-Under-hood ABS Fuse/Relay Box Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Electrical Load Detector (ELD) Unit > Page 6906 Relay Box: Locations Under-Hood Fuse/Relay Box Photo Right Rear Corner Of Engine Compartment Under-Hood Fuse/Relay Box Fuse/Relay Information-Under-hood Fuse/Relay Box (Part 1 Of 2) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Electrical Load Detector (ELD) Unit > Page 6907 Fuse/Relay Information-Under-hood Fuse/Relay Box (Part 1 Of 2) Fuse/Relay Information-Under-hood Fuse/Relay Box (Part 2 Of 2) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Under-Dash Fuse/Relay Box Relay Box: Application and ID Under-Dash Fuse/Relay Box Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 1 Of 3) Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Under-Dash Fuse/Relay Box > Page 6910 Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 2 Of 3) Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 3 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Under-Dash Fuse/Relay Box > Page 6911 Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 3 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Under-Dash Fuse/Relay Box > Page 6912 Relay Box: Application and ID Under-Hood ABS Fuse/Relay Box Fuse/Relay Information-Under-hood ABS Fuse/Relay Box Fuse/Relay Information-Under-hood ABS Fuse/Relay Box Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Under-Dash Fuse/Relay Box > Page 6913 Relay Box: Application and ID Under-Hood Fuse/Relay Box Fuse/Relay Information-Under-hood Fuse/Relay Box (Part 1 Of 2) Fuse/Relay Information-Under-hood Fuse/Relay Box (Part 1 Of 2) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Under-Dash Fuse/Relay Box > Page 6914 Fuse/Relay Information-Under-hood Fuse/Relay Box (Part 2 Of 2) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Electrical Load Detector (ELD) Unit Relay Box: Locations Electrical Load Detector (ELD) Unit Bottom Of Under-hood Fuse/Relay Box Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Electrical Load Detector (ELD) Unit > Page 6919 Relay Box: Locations Under-Dash Fuse/Relay Box Photo Behind Left Side Of Dash Under Dash Fuse/Relay Box Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Electrical Load Detector (ELD) Unit > Page 6920 Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Electrical Load Detector (ELD) Unit > Page 6921 Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 2 Of 3) Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 3 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Electrical Load Detector (ELD) Unit > Page 6922 Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 3 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Electrical Load Detector (ELD) Unit > Page 6923 Relay Box: Locations Under-Hood ABS Fuse/Relay Box Photo Right Side Of Engine Compartment Fuse/Relay Information-Under-hood ABS Fuse/Relay Box Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Electrical Load Detector (ELD) Unit > Page 6924 Fuse/Relay Information-Under-hood ABS Fuse/Relay Box Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Electrical Load Detector (ELD) Unit > Page 6925 Relay Box: Locations Under-Hood Fuse/Relay Box Photo Right Rear Corner Of Engine Compartment Under-Hood Fuse/Relay Box Fuse/Relay Information-Under-hood Fuse/Relay Box (Part 1 Of 2) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Electrical Load Detector (ELD) Unit > Page 6926 Fuse/Relay Information-Under-hood Fuse/Relay Box (Part 1 Of 2) Fuse/Relay Information-Under-hood Fuse/Relay Box (Part 2 Of 2) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Under-Dash Fuse/Relay Box Relay Box: Application and ID Under-Dash Fuse/Relay Box Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 1 Of 3) Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Under-Dash Fuse/Relay Box > Page 6929 Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 2 Of 3) Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 3 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Under-Dash Fuse/Relay Box > Page 6930 Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 3 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Under-Dash Fuse/Relay Box > Page 6931 Relay Box: Application and ID Under-Hood ABS Fuse/Relay Box Fuse/Relay Information-Under-hood ABS Fuse/Relay Box Fuse/Relay Information-Under-hood ABS Fuse/Relay Box Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Under-Dash Fuse/Relay Box > Page 6932 Relay Box: Application and ID Under-Hood Fuse/Relay Box Fuse/Relay Information-Under-hood Fuse/Relay Box (Part 1 Of 2) Fuse/Relay Information-Under-hood Fuse/Relay Box (Part 1 Of 2) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Under-Dash Fuse/Relay Box > Page 6933 Fuse/Relay Information-Under-hood Fuse/Relay Box (Part 2 Of 2) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Under-Dash Fuse/Relay Box Fuse: Locations Under-Dash Fuse/Relay Box Photo Behind Left Side Of Dash Under Dash Fuse/Relay Box Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Under-Dash Fuse/Relay Box > Page 6939 Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Under-Dash Fuse/Relay Box > Page 6940 Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 2 Of 3) Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 3 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Under-Dash Fuse/Relay Box > Page 6941 Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 3 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Under-Dash Fuse/Relay Box > Page 6942 Fuse: Locations Under-Hood Fuse/Relay Box Right Rear Corner Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Under-Dash Fuse/Relay Box > Page 6943 Fuse: Locations Under-Hood ABS Fuse/Relay Box Fuse/Relay Information-Under-hood ABS Fuse/Relay Box Right Side Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Under Dash Fuse/Relay Box Fuse: Application and ID Under Dash Fuse/Relay Box Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 1 Of 3) Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Under Dash Fuse/Relay Box > Page 6946 Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 2 Of 3) Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 3 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Under Dash Fuse/Relay Box > Page 6947 Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 3 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Under Dash Fuse/Relay Box > Page 6948 Fuse: Application and ID Under-Dash Fuse/Relay Box Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 1 Of 3) Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Under Dash Fuse/Relay Box > Page 6949 Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 2 Of 3) Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 3 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Under Dash Fuse/Relay Box > Page 6950 Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 3 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Under Dash Fuse/Relay Box > Page 6951 Fuse: Application and ID Under-Hood ABS Fuse/Relay Box Fuse/Relay Information-Under-hood ABS Fuse/Relay Box Fuse/Relay Information-Under-hood ABS Fuse/Relay Box Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Under Dash Fuse/Relay Box > Page 6952 Fuse: Application and ID Under-Hood Fuse/Relay Box Fuse/Relay Information-Under-hood Fuse/Relay Box (Part 1 Of 2) Fuse/Relay Information-Under-hood Fuse/Relay Box (Part 1 Of 2) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Under Dash Fuse/Relay Box > Page 6953 Fuse/Relay Information-Under-hood Fuse/Relay Box (Part 2 Of 2) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > SRS Fuse Block Fuse Block: Locations SRS Fuse Block Behind Left Side Of Dash Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > SRS Fuse Block > Page 6958 Fuse Block: Locations Under-Dash Fuse/Relay Box Behind Left Side Of Dash Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > SRS Fuse Block > Page 6959 Fuse Block: Locations Under-Hood ABS Fuse/Relay Box Right Side Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > SRS Fuse Block > Page 6960 Fuse Block: Locations Under-Hood Fuse/Relay Box Right Rear Corner Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Under-Hood ABS Fuse/Relay Box Fuse Block: Application and ID Under-Hood ABS Fuse/Relay Box Fuse/Relay Information-Under-hood ABS Fuse/Relay Box Fuse/Relay Information-Under-hood ABS Fuse/Relay Box Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Under-Hood ABS Fuse/Relay Box > Page 6963 Fuse Block: Application and ID Under-Dash Fuse/Relay Box Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 1 Of 3) Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Under-Hood ABS Fuse/Relay Box > Page 6964 Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 2 Of 3) Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 3 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Under-Hood ABS Fuse/Relay Box > Page 6965 Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 3 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Under-Hood ABS Fuse/Relay Box > Page 6966 Fuse Block: Application and ID Under-Hood Fuse/Relay Box Fuse/Relay Information-Under-hood Fuse/Relay Box (Part 1 Of 2) Fuse/Relay Information-Under-hood Fuse/Relay Box (Part 1 Of 2) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Under-Hood ABS Fuse/Relay Box > Page 6967 Fuse/Relay Information-Under-hood Fuse/Relay Box (Part 2 Of 2) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Locations > Photo 23 Multiple Junction Connector: Locations Photo 23 Left Rear Corner Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Locations > Photo 23 > Page 6972 Multiple Junction Connector: Locations Photo 54 Left Kick Panel Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Locations > Photo 23 > Page 6973 Multiple Junction Connector: Locations Photo 63 Behind Left Side Of Dash Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Electrical Load Detector (ELD) Unit Relay Box: Locations Electrical Load Detector (ELD) Unit Bottom Of Under-hood Fuse/Relay Box Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Electrical Load Detector (ELD) Unit > Page 6979 Relay Box: Locations Under-Dash Fuse/Relay Box Photo Behind Left Side Of Dash Under Dash Fuse/Relay Box Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Electrical Load Detector (ELD) Unit > Page 6980 Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Electrical Load Detector (ELD) Unit > Page 6981 Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 2 Of 3) Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 3 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Electrical Load Detector (ELD) Unit > Page 6982 Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 3 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Electrical Load Detector (ELD) Unit > Page 6983 Relay Box: Locations Under-Hood ABS Fuse/Relay Box Photo Right Side Of Engine Compartment Fuse/Relay Information-Under-hood ABS Fuse/Relay Box Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Electrical Load Detector (ELD) Unit > Page 6984 Fuse/Relay Information-Under-hood ABS Fuse/Relay Box Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Electrical Load Detector (ELD) Unit > Page 6985 Relay Box: Locations Under-Hood Fuse/Relay Box Photo Right Rear Corner Of Engine Compartment Under-Hood Fuse/Relay Box Fuse/Relay Information-Under-hood Fuse/Relay Box (Part 1 Of 2) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Electrical Load Detector (ELD) Unit > Page 6986 Fuse/Relay Information-Under-hood Fuse/Relay Box (Part 1 Of 2) Fuse/Relay Information-Under-hood Fuse/Relay Box (Part 2 Of 2) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Under-Dash Fuse/Relay Box Relay Box: Application and ID Under-Dash Fuse/Relay Box Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 1 Of 3) Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Under-Dash Fuse/Relay Box > Page 6989 Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 2 Of 3) Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 3 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Under-Dash Fuse/Relay Box > Page 6990 Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 3 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Under-Dash Fuse/Relay Box > Page 6991 Relay Box: Application and ID Under-Hood ABS Fuse/Relay Box Fuse/Relay Information-Under-hood ABS Fuse/Relay Box Fuse/Relay Information-Under-hood ABS Fuse/Relay Box Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Under-Dash Fuse/Relay Box > Page 6992 Relay Box: Application and ID Under-Hood Fuse/Relay Box Fuse/Relay Information-Under-hood Fuse/Relay Box (Part 1 Of 2) Fuse/Relay Information-Under-hood Fuse/Relay Box (Part 1 Of 2) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Under-Dash Fuse/Relay Box > Page 6993 Fuse/Relay Information-Under-hood Fuse/Relay Box (Part 2 Of 2) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Electrical Load Detector (ELD) Unit Relay Box: Locations Electrical Load Detector (ELD) Unit Bottom Of Under-hood Fuse/Relay Box Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Electrical Load Detector (ELD) Unit > Page 6998 Relay Box: Locations Under-Dash Fuse/Relay Box Photo Behind Left Side Of Dash Under Dash Fuse/Relay Box Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Electrical Load Detector (ELD) Unit > Page 6999 Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Electrical Load Detector (ELD) Unit > Page 7000 Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 2 Of 3) Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 3 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Electrical Load Detector (ELD) Unit > Page 7001 Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 3 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Electrical Load Detector (ELD) Unit > Page 7002 Relay Box: Locations Under-Hood ABS Fuse/Relay Box Photo Right Side Of Engine Compartment Fuse/Relay Information-Under-hood ABS Fuse/Relay Box Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Electrical Load Detector (ELD) Unit > Page 7003 Fuse/Relay Information-Under-hood ABS Fuse/Relay Box Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Electrical Load Detector (ELD) Unit > Page 7004 Relay Box: Locations Under-Hood Fuse/Relay Box Photo Right Rear Corner Of Engine Compartment Under-Hood Fuse/Relay Box Fuse/Relay Information-Under-hood Fuse/Relay Box (Part 1 Of 2) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Electrical Load Detector (ELD) Unit > Page 7005 Fuse/Relay Information-Under-hood Fuse/Relay Box (Part 1 Of 2) Fuse/Relay Information-Under-hood Fuse/Relay Box (Part 2 Of 2) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Under-Dash Fuse/Relay Box Relay Box: Application and ID Under-Dash Fuse/Relay Box Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 1 Of 3) Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Under-Dash Fuse/Relay Box > Page 7008 Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 2 Of 3) Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 3 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Under-Dash Fuse/Relay Box > Page 7009 Fuse/Relay Information-Under-dash Fuse/Relay Box (Part 3 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Under-Dash Fuse/Relay Box > Page 7010 Relay Box: Application and ID Under-Hood ABS Fuse/Relay Box Fuse/Relay Information-Under-hood ABS Fuse/Relay Box Fuse/Relay Information-Under-hood ABS Fuse/Relay Box Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Under-Dash Fuse/Relay Box > Page 7011 Relay Box: Application and ID Under-Hood Fuse/Relay Box Fuse/Relay Information-Under-hood Fuse/Relay Box (Part 1 Of 2) Fuse/Relay Information-Under-hood Fuse/Relay Box (Part 1 Of 2) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Under-Dash Fuse/Relay Box > Page 7012 Fuse/Relay Information-Under-hood Fuse/Relay Box (Part 2 Of 2) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right Alignment: Customer Interest Steering/Suspension - Vehicle Pulls Left/Right 06-068 May 2, 2009 Applies To: ALL *Vehicle Pulls or Drifts, and/or Steering Wheel Is Off-Center (Supersedes 06-068, Vehicle Pulling or Drifting, dated October 4, 2007, to revise the information marked by asterisks) (Replaces 90-011, Steering Wheel Off-Center Adjustment at PDI)* *REVISION SUMMARY The title description was revised.* SYMPTOM While driving on a straight road, the vehicle pulls or drifts to the right or left. BACKGROUND New tools were developed to help you diagnose and correct a pulling and/or steering wheel off-center issue. There is a diagnosis worksheet included to take on your test-drive and record your findings. These values are used to build the 15-digit DTC (diagnostic trouble code) that is required for your warranty claim. The last step in each repair procedure helps you create the correct code. In the rare case that you have to repair a vehicle that pulls and has the steering wheel off-center, use REPAIR PROCEDURE B to file your warranty claim. For more information, refer to Training Module SSC 44 - Steering Drift or Pull Interactive Service Bulletin. PROBABLE CAUSES Several conditions can cause the vehicle to pull or drift: ^ Wheel alignment ^ Tires ^ Off-center steering wheel (no pulling or drifting, but a customer may believe this is the case) CORRECTIVE ACTION Diagnose the problem using the special tools and the worksheet on page 4 that guides you to one of four repair procedures. TOOL INFORMATION Centering Tape (enough to diagnose 240 vehicles): T/N O7AAJ-001A300 Steering Drift Set Level: T/N 07AAJ-00100 Steering Drift Set: T/N O7MJ-001A140 Replacement Weight for Steering Drift Set: T/N 07AAJ-001A400 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 53560-SDA-AO1 H/C 7139652 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 7022 Defect Code: 07406 Symptom Code: 03602 Skill Level: Repair Technician Diagnostic Trouble Code: To create the 15-digit DTC, see the applicable repair procedure. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. TOOL DESCRIPTIONS The holding force gauge measures the amount of pull on the vehicle. It is a bracket that counts as one weight, plus five removable weights. During the test-drive, attach the bracket and the weights to the steering wheel on the side opposite the pulling direction. For example, if the vehicle pulls to the right, attach the bracket and weights to the left side of the steering wheel. Start with the maximum amount of weight on the steering wheel, and remove the weights until the vehicle drives in a straight line. When recording the pull on the worksheet, write down the direction of the pull (lefi or right) and the number of weights required to balance the pull (one through six). For example, if you have the bracket and two weights on the steering wheel, then record this as three weights. NOTE: The bracket counts as one weight. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 7023 The road crown gauge measures the amount of road crown. Almost all roads have a crown to help drain water during rainstorms. Use the suction cup to attach the road crown gauge bracket to the vehicle in a vertical position. If necessary, bend the bracket until the gauge is vertical. Once you attach and align the road crown gauge, calibrate the gauge to zero. There are two ways to calibrate the gauge: ^ Park the vehicle on a level surface, such as an alignment rack, and calibrate the gauge by moving the gauge until the ball is on the zero mark. ^ If you do not have a perfectly flat surface, park the vehicle on a reasonably flat surface and note the gauge reading. Turn the vehicle 1800 and, with the tires in the same spot, note the new gauge reading. Then move the gauge half of the difference. For example, if your first reading is +3 and, after moving the vehicle, the gauge reads -1, then the difference is 4 degrees. Position the gauge to read +1. NOTE: You must calibrate the gauge with the same weight in the vehicle that you will use for the test-drive. If you plan to have an assistant help you during the test-drive, calibrate the gauge while both of you are sitting in the vehicle. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 7024 The steering wheel offset gauge is a sticker that attaches to the steering wheel and the steering column cover. Place the sticker on the steering wheel when the steering wheel is straight. When you test-drive the vehicle, you can read how many millimeters the steering wheel is off-center. NOTE: If the vehicle is pulling, repairing the pull may correct the steering wheel offset. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 7025 DIAGNOSTIC WORKSHEET REPAIR PROCEDURE A Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 7026 NOTE: Do this repair procedure if, after doing step 10 of the test-drive, the vehicle pulled in the opposite direction after you swapped the front tires. 1. Swap wheels 2 and 4 on the passenger's side of the vehicle, and test-drive again. ^ If the pull goes away, replace the tire on wheel 2, then go to step 3. ^ If the pull does not go away, put wheels 2 and 4 back to their original positions, and go to step 2. 2. Swap wheels 1 and 3 on the driver's side of the vehicle, and test-drive again. ^ If the pull goes away, replace the tire on wheel 1, then go to step 3. ^ If the pull does not go away, use a known-good tire in position 1 and continue diagnosis. 3. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. REPAIR PROCEDURE B Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 7027 1. Place the vehicle on a commercially available, computerized, four-wheel alignment rack, and record the following measurements. Follow the equipment manufacturer's instructions. NOTE: Enter each reading in decimal degrees. Example 30' = 0.50. 2. If any measurement is out of specification, inspect the front suspension for any damage. Repair any damaged parts before continuing your diagnosis. 3. Determine how the front wheel camber is affecting the pull. Pick the combination of left- and right-front camber that best matches the vehicle you are repairing, then note the camber thrust direction for that combination: NOTE: ^ If the camber of both front wheels is negative, but one wheel is grossly more negative than the other, the camber thrust direction will be opposite the wheel with more negative camber (for example, if the left-front wheel is more negative, the camber thrust direction is right). ^ If the camber of both front wheels is positive, but one wheel is grossly more positive than the other, the camber thrust direction will be the same as the wheel with more positive camber (for example, if the left-front wheel is more positive, the camber thrust direction is left). 4. Determine how the camber needs to be adjusted. 5. Adjust the camber as needed. Front Camber Adjustment, Double Wishbone Suspension Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 7028 ^ Loosen the front subframe bolts. See the applicable service manual for more information. NOTE: The front wheels are being viewed from the rear of the vehicle. ^ Depending which way you need to shift the subframe, insert a pry bar between the subframe and body at both the front and rear positions of the subframe. NOTE: Be careful not to damage the vehicle. You could bend and damage the frame and/or body if you apply too much pressure. ^ Press on both pry bars to shift the subframe. It will move only a few millimeters. This should adjust the camber about 0.2-0.5°. ^ While holding the subframe in place, have an assistant torque the subframe bolts to their proper torque. Front Camber Adjustment, Strut Suspension ^ Raise the vehicle, and remove the front tires. ^ Loosen the damper pinch bolts and the flange nuts. ^ Adjust the camber by moving the bottom of the damper within the range of the damper pinch bolt free play. NOTE: Some vehicles have special pinch bolts that allow more adjustment. For more information, refer to the parts catalog. ^ Tighten the damper pinch bolts to the specified torque. ^ Reinstall the front wheels and lower the vehicle. Bounce the front of the vehicle several times to stabilize the suspension. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 7029 6. Test-drive the vehicle to make sure it no longer pulls. If the steering wheel is now off-center by more than 2 mm, go to REPAIR PROCEDURE C. 7. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. NOTE: Enter each reading in decimal degrees. Example 30' = 0.50. REPAIR PROCEDURE C 1. Make sure the steering wheel is centered. ^ Turn the steering wheel all the way to the right until it stops. ^ Turn the steering wheel all the way to the left, and count the number of revolutions until it stops. ^ Divide the number of revolutions in half, and turn the steering wheel until it is centered. For example, if it takes four revolutions of the steering wheel to go from lock to lock, then two turns is centered. ^ If the steering wheel is off-center by a large amount (20 mm or more), it may not be centered on the steering column shaft. Reinstall the steering wheel before going to step 2. 2. Place the vehicle on a lift, turn the steering wheel until it is centered, and then raise the vehicle. 3. Adjust the tie-rods. Use your measurements from question 13 of the test-drive to make your adjustment. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 7030 ^ If the wheels are pointed to the right, shorten the driver's side tie-rod, and lengthen the passenger's side. ^ If the wheels are pointed to the left, shorten the passenger's side tie-rod, and lengthen the driver's side. ^ Each 360° turn of the tie-rod equals about 8 mm of steering wheel adjustment. For example, a steering wheel is off-center by 4 mm with the front wheels pointed right (when the steering wheel is centered). To correct the off-center, shorten the driver's side tie-rod by a half-turn, and lengthen the passenger's side tie-rod by a half-turn. 4. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right Alignment: All Technical Service Bulletins Steering/Suspension - Vehicle Pulls Left/Right 06-068 May 2, 2009 Applies To: ALL *Vehicle Pulls or Drifts, and/or Steering Wheel Is Off-Center (Supersedes 06-068, Vehicle Pulling or Drifting, dated October 4, 2007, to revise the information marked by asterisks) (Replaces 90-011, Steering Wheel Off-Center Adjustment at PDI)* *REVISION SUMMARY The title description was revised.* SYMPTOM While driving on a straight road, the vehicle pulls or drifts to the right or left. BACKGROUND New tools were developed to help you diagnose and correct a pulling and/or steering wheel off-center issue. There is a diagnosis worksheet included to take on your test-drive and record your findings. These values are used to build the 15-digit DTC (diagnostic trouble code) that is required for your warranty claim. The last step in each repair procedure helps you create the correct code. In the rare case that you have to repair a vehicle that pulls and has the steering wheel off-center, use REPAIR PROCEDURE B to file your warranty claim. For more information, refer to Training Module SSC 44 - Steering Drift or Pull Interactive Service Bulletin. PROBABLE CAUSES Several conditions can cause the vehicle to pull or drift: ^ Wheel alignment ^ Tires ^ Off-center steering wheel (no pulling or drifting, but a customer may believe this is the case) CORRECTIVE ACTION Diagnose the problem using the special tools and the worksheet on page 4 that guides you to one of four repair procedures. TOOL INFORMATION Centering Tape (enough to diagnose 240 vehicles): T/N O7AAJ-001A300 Steering Drift Set Level: T/N 07AAJ-00100 Steering Drift Set: T/N O7MJ-001A140 Replacement Weight for Steering Drift Set: T/N 07AAJ-001A400 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 53560-SDA-AO1 H/C 7139652 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 7036 Defect Code: 07406 Symptom Code: 03602 Skill Level: Repair Technician Diagnostic Trouble Code: To create the 15-digit DTC, see the applicable repair procedure. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. TOOL DESCRIPTIONS The holding force gauge measures the amount of pull on the vehicle. It is a bracket that counts as one weight, plus five removable weights. During the test-drive, attach the bracket and the weights to the steering wheel on the side opposite the pulling direction. For example, if the vehicle pulls to the right, attach the bracket and weights to the left side of the steering wheel. Start with the maximum amount of weight on the steering wheel, and remove the weights until the vehicle drives in a straight line. When recording the pull on the worksheet, write down the direction of the pull (lefi or right) and the number of weights required to balance the pull (one through six). For example, if you have the bracket and two weights on the steering wheel, then record this as three weights. NOTE: The bracket counts as one weight. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 7037 The road crown gauge measures the amount of road crown. Almost all roads have a crown to help drain water during rainstorms. Use the suction cup to attach the road crown gauge bracket to the vehicle in a vertical position. If necessary, bend the bracket until the gauge is vertical. Once you attach and align the road crown gauge, calibrate the gauge to zero. There are two ways to calibrate the gauge: ^ Park the vehicle on a level surface, such as an alignment rack, and calibrate the gauge by moving the gauge until the ball is on the zero mark. ^ If you do not have a perfectly flat surface, park the vehicle on a reasonably flat surface and note the gauge reading. Turn the vehicle 1800 and, with the tires in the same spot, note the new gauge reading. Then move the gauge half of the difference. For example, if your first reading is +3 and, after moving the vehicle, the gauge reads -1, then the difference is 4 degrees. Position the gauge to read +1. NOTE: You must calibrate the gauge with the same weight in the vehicle that you will use for the test-drive. If you plan to have an assistant help you during the test-drive, calibrate the gauge while both of you are sitting in the vehicle. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 7038 The steering wheel offset gauge is a sticker that attaches to the steering wheel and the steering column cover. Place the sticker on the steering wheel when the steering wheel is straight. When you test-drive the vehicle, you can read how many millimeters the steering wheel is off-center. NOTE: If the vehicle is pulling, repairing the pull may correct the steering wheel offset. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 7039 DIAGNOSTIC WORKSHEET REPAIR PROCEDURE A Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 7040 NOTE: Do this repair procedure if, after doing step 10 of the test-drive, the vehicle pulled in the opposite direction after you swapped the front tires. 1. Swap wheels 2 and 4 on the passenger's side of the vehicle, and test-drive again. ^ If the pull goes away, replace the tire on wheel 2, then go to step 3. ^ If the pull does not go away, put wheels 2 and 4 back to their original positions, and go to step 2. 2. Swap wheels 1 and 3 on the driver's side of the vehicle, and test-drive again. ^ If the pull goes away, replace the tire on wheel 1, then go to step 3. ^ If the pull does not go away, use a known-good tire in position 1 and continue diagnosis. 3. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. REPAIR PROCEDURE B Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 7041 1. Place the vehicle on a commercially available, computerized, four-wheel alignment rack, and record the following measurements. Follow the equipment manufacturer's instructions. NOTE: Enter each reading in decimal degrees. Example 30' = 0.50. 2. If any measurement is out of specification, inspect the front suspension for any damage. Repair any damaged parts before continuing your diagnosis. 3. Determine how the front wheel camber is affecting the pull. Pick the combination of left- and right-front camber that best matches the vehicle you are repairing, then note the camber thrust direction for that combination: NOTE: ^ If the camber of both front wheels is negative, but one wheel is grossly more negative than the other, the camber thrust direction will be opposite the wheel with more negative camber (for example, if the left-front wheel is more negative, the camber thrust direction is right). ^ If the camber of both front wheels is positive, but one wheel is grossly more positive than the other, the camber thrust direction will be the same as the wheel with more positive camber (for example, if the left-front wheel is more positive, the camber thrust direction is left). 4. Determine how the camber needs to be adjusted. 5. Adjust the camber as needed. Front Camber Adjustment, Double Wishbone Suspension Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 7042 ^ Loosen the front subframe bolts. See the applicable service manual for more information. NOTE: The front wheels are being viewed from the rear of the vehicle. ^ Depending which way you need to shift the subframe, insert a pry bar between the subframe and body at both the front and rear positions of the subframe. NOTE: Be careful not to damage the vehicle. You could bend and damage the frame and/or body if you apply too much pressure. ^ Press on both pry bars to shift the subframe. It will move only a few millimeters. This should adjust the camber about 0.2-0.5°. ^ While holding the subframe in place, have an assistant torque the subframe bolts to their proper torque. Front Camber Adjustment, Strut Suspension ^ Raise the vehicle, and remove the front tires. ^ Loosen the damper pinch bolts and the flange nuts. ^ Adjust the camber by moving the bottom of the damper within the range of the damper pinch bolt free play. NOTE: Some vehicles have special pinch bolts that allow more adjustment. For more information, refer to the parts catalog. ^ Tighten the damper pinch bolts to the specified torque. ^ Reinstall the front wheels and lower the vehicle. Bounce the front of the vehicle several times to stabilize the suspension. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 7043 6. Test-drive the vehicle to make sure it no longer pulls. If the steering wheel is now off-center by more than 2 mm, go to REPAIR PROCEDURE C. 7. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. NOTE: Enter each reading in decimal degrees. Example 30' = 0.50. REPAIR PROCEDURE C 1. Make sure the steering wheel is centered. ^ Turn the steering wheel all the way to the right until it stops. ^ Turn the steering wheel all the way to the left, and count the number of revolutions until it stops. ^ Divide the number of revolutions in half, and turn the steering wheel until it is centered. For example, if it takes four revolutions of the steering wheel to go from lock to lock, then two turns is centered. ^ If the steering wheel is off-center by a large amount (20 mm or more), it may not be centered on the steering column shaft. Reinstall the steering wheel before going to step 2. 2. Place the vehicle on a lift, turn the steering wheel until it is centered, and then raise the vehicle. 3. Adjust the tie-rods. Use your measurements from question 13 of the test-drive to make your adjustment. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 7044 ^ If the wheels are pointed to the right, shorten the driver's side tie-rod, and lengthen the passenger's side. ^ If the wheels are pointed to the left, shorten the passenger's side tie-rod, and lengthen the driver's side. ^ Each 360° turn of the tie-rod equals about 8 mm of steering wheel adjustment. For example, a steering wheel is off-center by 4 mm with the front wheels pointed right (when the steering wheel is centered). To correct the off-center, shorten the driver's side tie-rod by a half-turn, and lengthen the passenger's side tie-rod by a half-turn. 4. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 7045 Alignment: By Symptom Technical Service Bulletin # 06-068 Date: 090502 Steering/Suspension - Vehicle Pulls Left/Right 06-068 May 2, 2009 Applies To: ALL *Vehicle Pulls or Drifts, and/or Steering Wheel Is Off-Center (Supersedes 06-068, Vehicle Pulling or Drifting, dated October 4, 2007, to revise the information marked by asterisks) (Replaces 90-011, Steering Wheel Off-Center Adjustment at PDI)* *REVISION SUMMARY The title description was revised.* SYMPTOM While driving on a straight road, the vehicle pulls or drifts to the right or left. BACKGROUND New tools were developed to help you diagnose and correct a pulling and/or steering wheel off-center issue. There is a diagnosis worksheet included to take on your test-drive and record your findings. These values are used to build the 15-digit DTC (diagnostic trouble code) that is required for your warranty claim. The last step in each repair procedure helps you create the correct code. In the rare case that you have to repair a vehicle that pulls and has the steering wheel off-center, use REPAIR PROCEDURE B to file your warranty claim. For more information, refer to Training Module SSC 44 - Steering Drift or Pull Interactive Service Bulletin. PROBABLE CAUSES Several conditions can cause the vehicle to pull or drift: ^ Wheel alignment ^ Tires ^ Off-center steering wheel (no pulling or drifting, but a customer may believe this is the case) CORRECTIVE ACTION Diagnose the problem using the special tools and the worksheet on page 4 that guides you to one of four repair procedures. TOOL INFORMATION Centering Tape (enough to diagnose 240 vehicles): T/N O7AAJ-001A300 Steering Drift Set Level: T/N 07AAJ-00100 Steering Drift Set: T/N O7MJ-001A140 Replacement Weight for Steering Drift Set: T/N 07AAJ-001A400 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 7046 Failed Part: P/N 53560-SDA-AO1 H/C 7139652 Defect Code: 07406 Symptom Code: 03602 Skill Level: Repair Technician Diagnostic Trouble Code: To create the 15-digit DTC, see the applicable repair procedure. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. TOOL DESCRIPTIONS The holding force gauge measures the amount of pull on the vehicle. It is a bracket that counts as one weight, plus five removable weights. During the test-drive, attach the bracket and the weights to the steering wheel on the side opposite the pulling direction. For example, if the vehicle pulls to the right, attach the bracket and weights to the left side of the steering wheel. Start with the maximum amount of weight on the steering wheel, and remove the weights until the vehicle drives in a straight line. When recording the pull on the worksheet, write down the direction of the pull (lefi or right) and the number of weights required to balance the pull (one through six). For example, if you have the bracket and two weights on the steering wheel, then record this as three weights. NOTE: The bracket counts as one weight. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 7047 The road crown gauge measures the amount of road crown. Almost all roads have a crown to help drain water during rainstorms. Use the suction cup to attach the road crown gauge bracket to the vehicle in a vertical position. If necessary, bend the bracket until the gauge is vertical. Once you attach and align the road crown gauge, calibrate the gauge to zero. There are two ways to calibrate the gauge: ^ Park the vehicle on a level surface, such as an alignment rack, and calibrate the gauge by moving the gauge until the ball is on the zero mark. ^ If you do not have a perfectly flat surface, park the vehicle on a reasonably flat surface and note the gauge reading. Turn the vehicle 1800 and, with the tires in the same spot, note the new gauge reading. Then move the gauge half of the difference. For example, if your first reading is +3 and, after moving the vehicle, the gauge reads -1, then the difference is 4 degrees. Position the gauge to read +1. NOTE: You must calibrate the gauge with the same weight in the vehicle that you will use for the test-drive. If you plan to have an assistant help you during the test-drive, calibrate the gauge while both of you are sitting in the vehicle. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 7048 The steering wheel offset gauge is a sticker that attaches to the steering wheel and the steering column cover. Place the sticker on the steering wheel when the steering wheel is straight. When you test-drive the vehicle, you can read how many millimeters the steering wheel is off-center. NOTE: If the vehicle is pulling, repairing the pull may correct the steering wheel offset. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 7049 DIAGNOSTIC WORKSHEET REPAIR PROCEDURE A Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 7050 NOTE: Do this repair procedure if, after doing step 10 of the test-drive, the vehicle pulled in the opposite direction after you swapped the front tires. 1. Swap wheels 2 and 4 on the passenger's side of the vehicle, and test-drive again. ^ If the pull goes away, replace the tire on wheel 2, then go to step 3. ^ If the pull does not go away, put wheels 2 and 4 back to their original positions, and go to step 2. 2. Swap wheels 1 and 3 on the driver's side of the vehicle, and test-drive again. ^ If the pull goes away, replace the tire on wheel 1, then go to step 3. ^ If the pull does not go away, use a known-good tire in position 1 and continue diagnosis. 3. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. REPAIR PROCEDURE B Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 7051 1. Place the vehicle on a commercially available, computerized, four-wheel alignment rack, and record the following measurements. Follow the equipment manufacturer's instructions. NOTE: Enter each reading in decimal degrees. Example 30' = 0.50. 2. If any measurement is out of specification, inspect the front suspension for any damage. Repair any damaged parts before continuing your diagnosis. 3. Determine how the front wheel camber is affecting the pull. Pick the combination of left- and right-front camber that best matches the vehicle you are repairing, then note the camber thrust direction for that combination: NOTE: ^ If the camber of both front wheels is negative, but one wheel is grossly more negative than the other, the camber thrust direction will be opposite the wheel with more negative camber (for example, if the left-front wheel is more negative, the camber thrust direction is right). ^ If the camber of both front wheels is positive, but one wheel is grossly more positive than the other, the camber thrust direction will be the same as the wheel with more positive camber (for example, if the left-front wheel is more positive, the camber thrust direction is left). 4. Determine how the camber needs to be adjusted. 5. Adjust the camber as needed. Front Camber Adjustment, Double Wishbone Suspension Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 7052 ^ Loosen the front subframe bolts. See the applicable service manual for more information. NOTE: The front wheels are being viewed from the rear of the vehicle. ^ Depending which way you need to shift the subframe, insert a pry bar between the subframe and body at both the front and rear positions of the subframe. NOTE: Be careful not to damage the vehicle. You could bend and damage the frame and/or body if you apply too much pressure. ^ Press on both pry bars to shift the subframe. It will move only a few millimeters. This should adjust the camber about 0.2-0.5°. ^ While holding the subframe in place, have an assistant torque the subframe bolts to their proper torque. Front Camber Adjustment, Strut Suspension ^ Raise the vehicle, and remove the front tires. ^ Loosen the damper pinch bolts and the flange nuts. ^ Adjust the camber by moving the bottom of the damper within the range of the damper pinch bolt free play. NOTE: Some vehicles have special pinch bolts that allow more adjustment. For more information, refer to the parts catalog. ^ Tighten the damper pinch bolts to the specified torque. ^ Reinstall the front wheels and lower the vehicle. Bounce the front of the vehicle several times to stabilize the suspension. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 7053 6. Test-drive the vehicle to make sure it no longer pulls. If the steering wheel is now off-center by more than 2 mm, go to REPAIR PROCEDURE C. 7. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. NOTE: Enter each reading in decimal degrees. Example 30' = 0.50. REPAIR PROCEDURE C 1. Make sure the steering wheel is centered. ^ Turn the steering wheel all the way to the right until it stops. ^ Turn the steering wheel all the way to the left, and count the number of revolutions until it stops. ^ Divide the number of revolutions in half, and turn the steering wheel until it is centered. For example, if it takes four revolutions of the steering wheel to go from lock to lock, then two turns is centered. ^ If the steering wheel is off-center by a large amount (20 mm or more), it may not be centered on the steering column shaft. Reinstall the steering wheel before going to step 2. 2. Place the vehicle on a lift, turn the steering wheel until it is centered, and then raise the vehicle. 3. Adjust the tie-rods. Use your measurements from question 13 of the test-drive to make your adjustment. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 7054 ^ If the wheels are pointed to the right, shorten the driver's side tie-rod, and lengthen the passenger's side. ^ If the wheels are pointed to the left, shorten the passenger's side tie-rod, and lengthen the driver's side. ^ Each 360° turn of the tie-rod equals about 8 mm of steering wheel adjustment. For example, a steering wheel is off-center by 4 mm with the front wheels pointed right (when the steering wheel is centered). To correct the off-center, shorten the driver's side tie-rod by a half-turn, and lengthen the passenger's side tie-rod by a half-turn. 4. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. Technical Service Bulletin # 06-068 Date: 090502 Steering/Suspension - Vehicle Pulls Left/Right 06-068 May 2, 2009 Applies To: ALL *Vehicle Pulls or Drifts, and/or Steering Wheel Is Off-Center (Supersedes 06-068, Vehicle Pulling or Drifting, dated October 4, 2007, to revise the information marked by asterisks) (Replaces 90-011, Steering Wheel Off-Center Adjustment at PDI)* *REVISION SUMMARY The title description was revised.* SYMPTOM While driving on a straight road, the vehicle pulls or drifts to the right or left. BACKGROUND New tools were developed to help you diagnose and correct a pulling and/or steering wheel off-center issue. There is a diagnosis worksheet included to take on your test-drive and record your findings. These values are used to build the 15-digit DTC (diagnostic trouble code) that is required for your warranty claim. The last step in each repair procedure helps you create the correct code. In the rare case that you have to repair a vehicle that pulls and has the steering wheel off-center, use REPAIR PROCEDURE B to file your warranty claim. For more information, refer to Training Module SSC 44 - Steering Drift or Pull Interactive Service Bulletin. PROBABLE CAUSES Several conditions can cause the vehicle to pull or drift: ^ Wheel alignment ^ Tires ^ Off-center steering wheel (no pulling or drifting, but a customer may believe this is the case) CORRECTIVE ACTION Diagnose the problem using the special tools and the worksheet on page 4 that guides you to one of four repair procedures. TOOL INFORMATION Centering Tape (enough to diagnose 240 vehicles): T/N O7AAJ-001A300 Steering Drift Set Level: T/N 07AAJ-00100 Steering Drift Set: T/N O7MJ-001A140 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 7055 Replacement Weight for Steering Drift Set: T/N 07AAJ-001A400 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 53560-SDA-AO1 H/C 7139652 Defect Code: 07406 Symptom Code: 03602 Skill Level: Repair Technician Diagnostic Trouble Code: To create the 15-digit DTC, see the applicable repair procedure. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. TOOL DESCRIPTIONS The holding force gauge measures the amount of pull on the vehicle. It is a bracket that counts as one weight, plus five removable weights. During the test-drive, attach the bracket and the weights to the steering wheel on the side opposite the pulling direction. For example, if the vehicle pulls Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 7056 to the right, attach the bracket and weights to the left side of the steering wheel. Start with the maximum amount of weight on the steering wheel, and remove the weights until the vehicle drives in a straight line. When recording the pull on the worksheet, write down the direction of the pull (lefi or right) and the number of weights required to balance the pull (one through six). For example, if you have the bracket and two weights on the steering wheel, then record this as three weights. NOTE: The bracket counts as one weight. The road crown gauge measures the amount of road crown. Almost all roads have a crown to help drain water during rainstorms. Use the suction cup to attach the road crown gauge bracket to the vehicle in a vertical position. If necessary, bend the bracket until the gauge is vertical. Once you attach and align the road crown gauge, calibrate the gauge to zero. There are two ways to calibrate the gauge: ^ Park the vehicle on a level surface, such as an alignment rack, and calibrate the gauge by moving the gauge until the ball is on the zero mark. ^ If you do not have a perfectly flat surface, park the vehicle on a reasonably flat surface and note the gauge reading. Turn the vehicle 1800 and, with the tires in the same spot, note the new gauge reading. Then move the gauge half of the difference. For example, if your first reading is +3 and, after moving the vehicle, the gauge reads -1, then the difference is 4 degrees. Position the gauge to read +1. NOTE: You must calibrate the gauge with the same weight in the vehicle that you will use for the test-drive. If you plan to have an assistant help you during the test-drive, calibrate the gauge while both of you are sitting in the vehicle. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 7057 The steering wheel offset gauge is a sticker that attaches to the steering wheel and the steering column cover. Place the sticker on the steering wheel when the steering wheel is straight. When you test-drive the vehicle, you can read how many millimeters the steering wheel is off-center. NOTE: If the vehicle is pulling, repairing the pull may correct the steering wheel offset. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 7058 DIAGNOSTIC WORKSHEET REPAIR PROCEDURE A Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 7059 NOTE: Do this repair procedure if, after doing step 10 of the test-drive, the vehicle pulled in the opposite direction after you swapped the front tires. 1. Swap wheels 2 and 4 on the passenger's side of the vehicle, and test-drive again. ^ If the pull goes away, replace the tire on wheel 2, then go to step 3. ^ If the pull does not go away, put wheels 2 and 4 back to their original positions, and go to step 2. 2. Swap wheels 1 and 3 on the driver's side of the vehicle, and test-drive again. ^ If the pull goes away, replace the tire on wheel 1, then go to step 3. ^ If the pull does not go away, use a known-good tire in position 1 and continue diagnosis. 3. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. REPAIR PROCEDURE B Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 7060 1. Place the vehicle on a commercially available, computerized, four-wheel alignment rack, and record the following measurements. Follow the equipment manufacturer's instructions. NOTE: Enter each reading in decimal degrees. Example 30' = 0.50. 2. If any measurement is out of specification, inspect the front suspension for any damage. Repair any damaged parts before continuing your diagnosis. 3. Determine how the front wheel camber is affecting the pull. Pick the combination of left- and right-front camber that best matches the vehicle you are repairing, then note the camber thrust direction for that combination: NOTE: ^ If the camber of both front wheels is negative, but one wheel is grossly more negative than the other, the camber thrust direction will be opposite the wheel with more negative camber (for example, if the left-front wheel is more negative, the camber thrust direction is right). ^ If the camber of both front wheels is positive, but one wheel is grossly more positive than the other, the camber thrust direction will be the same as the wheel with more positive camber (for example, if the left-front wheel is more positive, the camber thrust direction is left). 4. Determine how the camber needs to be adjusted. 5. Adjust the camber as needed. Front Camber Adjustment, Double Wishbone Suspension Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 7061 ^ Loosen the front subframe bolts. See the applicable service manual for more information. NOTE: The front wheels are being viewed from the rear of the vehicle. ^ Depending which way you need to shift the subframe, insert a pry bar between the subframe and body at both the front and rear positions of the subframe. NOTE: Be careful not to damage the vehicle. You could bend and damage the frame and/or body if you apply too much pressure. ^ Press on both pry bars to shift the subframe. It will move only a few millimeters. This should adjust the camber about 0.2-0.5°. ^ While holding the subframe in place, have an assistant torque the subframe bolts to their proper torque. Front Camber Adjustment, Strut Suspension ^ Raise the vehicle, and remove the front tires. ^ Loosen the damper pinch bolts and the flange nuts. ^ Adjust the camber by moving the bottom of the damper within the range of the damper pinch bolt free play. NOTE: Some vehicles have special pinch bolts that allow more adjustment. For more information, refer to the parts catalog. ^ Tighten the damper pinch bolts to the specified torque. ^ Reinstall the front wheels and lower the vehicle. Bounce the front of the vehicle several times to stabilize the suspension. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 7062 6. Test-drive the vehicle to make sure it no longer pulls. If the steering wheel is now off-center by more than 2 mm, go to REPAIR PROCEDURE C. 7. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. NOTE: Enter each reading in decimal degrees. Example 30' = 0.50. REPAIR PROCEDURE C 1. Make sure the steering wheel is centered. ^ Turn the steering wheel all the way to the right until it stops. ^ Turn the steering wheel all the way to the left, and count the number of revolutions until it stops. ^ Divide the number of revolutions in half, and turn the steering wheel until it is centered. For example, if it takes four revolutions of the steering wheel to go from lock to lock, then two turns is centered. ^ If the steering wheel is off-center by a large amount (20 mm or more), it may not be centered on the steering column shaft. Reinstall the steering wheel before going to step 2. 2. Place the vehicle on a lift, turn the steering wheel until it is centered, and then raise the vehicle. 3. Adjust the tie-rods. Use your measurements from question 13 of the test-drive to make your adjustment. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 7063 ^ If the wheels are pointed to the right, shorten the driver's side tie-rod, and lengthen the passenger's side. ^ If the wheels are pointed to the left, shorten the passenger's side tie-rod, and lengthen the driver's side. ^ Each 360° turn of the tie-rod equals about 8 mm of steering wheel adjustment. For example, a steering wheel is off-center by 4 mm with the front wheels pointed right (when the steering wheel is centered). To correct the off-center, shorten the driver's side tie-rod by a half-turn, and lengthen the passenger's side tie-rod by a half-turn. 4. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Front Wheel Alignment Alignment: Specifications Front Wheel Alignment Caster Angle, Degrees Limits ................................................................................................................................................... ................................................ + 1/6 to +2 1/6 Desired ....................................................................... ........................................................................................................................................ +1 1/6 Camber Angle, Degrees Limits ................................................................................................................................................... ............................................................. -1 to +1 Desired ..................................................................... .................................................................................................................................................. 0 Toe-In, Inch ......................................................................................................................................... ................................................................................. 0 Wheel Turning Angle, Degrees Inner Wheel ......................................................................................................................................... ..................................................................... 41 Outer Wheel ............................................................. .......................................................................................................................................... 33 1/2 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Front Wheel Alignment > Page 7066 Alignment: Specifications Rear Wheel Alignment Camber Angle, Degrees Limits ................................................................................................................................................... .................................................. -1 1/3 to + 2/3 Desired ...................................................................... .............................................................................................................................................. -1/3 Toe-In, Inch ......................................................................................................................................... ............................................................................ 0.08 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 7067 Alignment: Service Precautions CAUTION: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The correct torque value must be used when installing fasteners that require it. If the above conditions are not followed, parts or system damage could result. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > General Description Alignment: Description and Operation General Description GENERAL DESCRIPTION "Front End Alignment" refers to the angular relationship between the front wheels, the front suspension attaching parts and the ground. Proper front end alignment must be maintained in order to insure efficient steering, good directional stability and to prevent abnormal tire wear. The most important factors of front end alignment are wheel toe-in, wheel camber and axle caster. CAMBER: Camber is the vertical tilting inward or outward of the front wheels. When the wheels tilt outward at the top, the camber is positive (+). When the wheels tilt inward at the top, the camber is negative (-). The amount of tilt measured in degrees from the vertical is called the camber angle (1). If camber is extreme or unequal between the wheels, improper steering and excessive tire wear will result. Negative camber causes wear on the inside of the tire, while positive camber causes wear to the outside. CASTER: This illustration shows view from the side of the vehicle. Caster (1) is the vertical tilting of the wheel axis either forward or backward (when viewed from the side of the vehicle). A backward tilt is positive (+) and a forward tilt is negative (-). On the short and long arm type suspension you cannot see a caster angle without a special instrument, but if you look straight down from the top of the upper control arm to the ground, the ball joints do not line up (fore and aft) when a caster angle other than 0 degree is present. With a positive angle, the lower ball joint would be slightly ahead (toward the front of the vehicle) of the upper ball joint center line. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > General Description > Page 7070 TOE-IN: This illustration shows view from the top of the vehicle. Toe-in is the measured amount the front wheels are turn in. The actual amount of toe-in is normally a fraction of a degree. Toe-in is measured from the center of the tire treads or from the inside of the tires. The purpose of toe-in is to insure parallel rolling of the front wheels and to offset any small deflections of the wheel support system which occurs when the vehicle is rolling forward. Incorrect toe-in results in excessive toe-in and unstable steering. Toe-in is the last alignment to be set in the front end alignment procedure. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > General Description > Page 7071 Alignment: Description and Operation Camber Camber is the inward or outward tilting of the front wheels from the vertical. When the wheels tilt outward at the top, the camber is positive (+). When the wheels tilt inward at the top, the camber is negative (-). The amount of tilt measured in degrees from the vertical is called the camber angle. If camber is extreme or unequal between the wheels, improper steering and excessive tire wear will result. Negative camber causes wear on the inside of the tire, while positive camber causes wear to the outside. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > General Description > Page 7072 Alignment: Description and Operation Caster Caster is the tilting of the wheel axis either forward or backward from the vertical (when viewed from the side of the vehicle). A backward tilt is positive (+) and a forward tilt is negative (-). On the short and long arm type suspension you cannot see a caster angle without a special instrument, but if you look straight down from the top of the upper control arm to the ground, the ball joints do not line up (fore and aft) when a caster angle other than 0 degree is present. With a positive angle, the lower ball joint would be slightly ahead (toward the front of the vehicle) of the upper ball joint center line. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > General Description > Page 7073 Alignment: Description and Operation Toe-In Toe-in is the turning of the front wheels. The actual amount of toe-in is normally a fraction of a degree. Toe-in is measured from the center of the tire treads or from the inside of the tires. The purpose of toe-in is to insure parallel rolling of the front wheels and to offset any small deflections of the wheel support system which occurs when the vehicle is rolling forward. Incorrect toe-in results in excessive toe-in and unstable steering. Toe-in is the last alignment to be set in the front end alignment procedure. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Page 7074 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Preliminary Checks Alignment: Service and Repair Preliminary Checks INSPECTION Before making any adjustments affecting caster, camber or toe-in, the following front end inspection should be made. 1. Inspect the tires for proper inflation pressure. 2. Inspect the front wheel bearings for proper adjustment. 3. inspect the ball joints and tie rod ends. If excessive looseness is noted, correct before adjusting. 4. Inspect the wheel and tires for run-out. 5. Inspect the trim height. If not within specifications, the correction must be made before adjusting caster. 6. Inspect the steering unit for looseness at the frame. 7. Inspect shock absorbers for leaks or any noticeable noise. 8. Inspect the control arms or stabilizer bar attachment for looseness. 9. Inspect the front end alignment using alignment equipment. Follow the manufacturer's instructions. 10. Alignment must be performed on a level surface. - Check that the suspension is not modified. - Check the tire size and tire pressure. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Preliminary Checks > Page 7077 Alignment: Service and Repair Alignment Camber Ensure tires are properly inflated prior to checking or adjusting camber angles. Camber angles are not adjustable, however, the following procedure may be used to ensure camber is within specifications. Fig. 1 Camber Angle Inspection 1. Remove spindle nut and install suitable camber gauge and adapter, Fig. 1, with wheels in straight-ahead position. 2. Note gauge reading with bubble centered on the gauge. If camber is not within specifications, inspect suspension components for damage and repair as necessary, then recheck camber. Caster Ensure tires are properly inflated prior to checking or adjusting caster angles. 1. Check steering wheel angle. If significantly off center, it may be necessary to remove steering wheel and reposition it on splines. Turn steering wheel to straight ahead position. 2. Check caster angle. 3. If caster angle is not within specifications, inspect suspension components for damage and repair as necessary, then recheck caster. Toe-In Ensure tires are properly inflated prior to checking or adjusting toe-in. 1. Center steering wheel, then loosen tie rod locknuts. 2. Turn both tie rods in the same direction until both front wheels are positioned straight ahead. 3. Adjust toe to specifications by turning both tie rods in the same direction, then tighten tie rod locknuts. Camber Ensure tires are properly inflated prior to checking or adjusting camber angles. Camber angles are not adjustable, however, the following procedure may be used to ensure camber is within specifications. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Preliminary Checks > Page 7078 Fig. 1 Camber Angle Inspection 1. Remove spindle nut and install suitable camber gauge and adapter, Fig. 1, with wheels in straight-ahead position. 2. Note gauge reading with bubble centered on the gauge. If camber is not within specifications, inspect suspension components for damage and repair as necessary, then recheck camber. Toe-In 1. Release parking brake. 2. Before adjustment, note location of compensator arm adjusting bolts. Fig. 4 Rear Toe-In Adjustment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Preliminary Checks > Page 7079 3. Loosen adjusting bolt and slide compensator arm in or out, Fig. 4, to adjust toe. 4. Torque adjusting bolt to 47 ft. lbs. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations Power Steering Pressure Switch: Locations Center Rear Of Engine Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 7085 Power Steering Pressure Switch: Diagrams For Connector Views refer to "Powertrain Management : Diagrams". Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 7086 Power Steering Pressure Switch: Description and Operation PURPOSE This signals the Engine Control Module (ECM) when the Power Steering load is high. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 7087 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair Front Steering Knuckle: Service and Repair 1. Raise and support front of vehicle, then remove front wheels. 2. Raise spindle nut locking tab, then remove spindle nut. 3. Remove brake hose bracket mounting bolts. 4. Remove caliper and position aside. Do not allow caliper assembly to hang from brake hose. 5. Remove brake disc attaching screws, then thread two 8 x 1.25 x 12 mm bolts into attaching screw holes to push disc from hub. When tightening screws, turn only two turns at a time to prevent excessively cocking the brake disc. 6. Remove brake disc from knuckle. 7. Remove speed sensor wire bracket, then the speed sensor from knuckle. 8. Remove tie rod end cotter pin and nut. 9. Remove tie rod end using suitable tie rod end remover. 10. Remove lower ball joint cotter pin, then loosen ball joint nut half way. 11. Using ball joint remover tool No. 07MAC-SL00200, or equivalent, separate ball joint and lower arm. 12. Remove upper ball joint shield, then the cotter pin and nut. 13. Separate upper ball joint from upper arm using suitable ball joint remover. 14. Remove steering knuckle and hub assembly by sliding off driveshaft. 15. Remove hub from steering knuckle using suitable press. 16. Remove knuckle ring, circlip and splash guard from knuckle. 17. Press out wheel bearing from hub using driver tool No. 07749-0010000, attachment tool No. 07746-0010500 and base tool No. 07GAF-SE00401, or equivalents. 18. Remove outboard bearing inner race from hub. Fig. 4 Front Suspension 19. Reverse procedure to install. Refer to Fig. 2 for tightening specifications. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair Power Steering Bleeding: Service and Repair When a power steering pump or gear has been installed, or an oil line has been disconnected, the air that has entered the system must be bled out before the vehicle is operated. If air is allowed to remain in the power steering fluid system, noisy and unsatisfactory operation of the system may result. When bleeding the system, and any time fluid is added to the power steering system, be sure to use only automatic transmission fluid labeled "DEXRON-IIE". 1. Fill the pump fluid reservoir to the proper label and let the fluid settle for at least two minutes. 2. Start the engine and let it run for a few seconds. Do not turn the steering wheel. Then turn the engine off. 3. Add fluid if necessary. 4. Repeat the above procedure until the fluid level remains constant after running the engine. 5. Raise the front end of the vehicle so that the front wheels are off the ground. 6. Start the engine. Slowly turn the steering wheel right and left, lightly contacting the wheel stops. 7. Add power steering fluid if necessary. 8. Bring down the vehicle, set the steering wheel at the straight forward position after turning it to its full steer positions 2 or 3 times, and stop the engine. 9. Stop the engine. Check the fluid level and refill as required. 10. If the fluid is extremely foamy, allow the vehicle to stand a few minutes and repeat the above procedure. 11. Inspect: a. Belt for tightness. b. Pulley for looseness or damage. The pulley should not wobble with the engine running. c. Hoses so they are not touching any other parts of the vehicle. d. Fluid level and fill to the proper level. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications Power Steering Fluid: Specifications Fluid Type ............................................................................................................................................ ....................... Genuine Honda Power Steering Fluid Always use Genuine Honda Power Steering Fluid. Using any other type of power steering fluid or automatic transmission fluid can cause increased wear and poor steering in cold weather. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pump: > 98-023 > Mar > 98 > Power Steering Pump - Fluid Leak Power Steering Pump: Customer Interest Power Steering Pump - Fluid Leak 98-023 March 9, 1998 Applies T0: 1994 - 97 Accord - ALL 1992 - 95 Civic - ALL 1995 - 96 Odyssey - ALL Leak From the Power Steering Pump SYMPTOM Fluid is leaking from the power steering pump between the pump housing and the cover. PROBABLE CAUSE The 0-ring between the pump housing and the cover is leaking. CORRECTIVE ACTION Replace the 0-ring between the pump housing and the cover. PARTS INFORMATION 0-ring (68.5 x 1.9 mm): P/N 91349-PY3-000, H/C 3676871 Genuine Honda Power Steering Fluid: P/N 08206-9002, H/C 3747284 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation number: 512711 Flat rate time: 0.8 hour Failed part: P/N 91349-PY3-000 H/C 3676871 Defect code: 060 Contention code: B06 Template ID: 98-023A Skill level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Remove the power steering pump. Refer to section 17 of the appropriate Service Manual. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pump: > 98-023 > Mar > 98 > Power Steering Pump - Fluid Leak > Page 7107 2. Remove the fours bolts that secure the pump cover to the pump housing, and remove the cover. 3. Remove the old 0-ring. Coat a new 0-ring with clean power steering fluid, and install the new 0-ring onto the pump cover. 4. Align the rollers with the holes in the pump cover, and install the cover. Torque the four mounting bolts to 20 N.m (14 lb-ft). 5. Reinstall the power steering pump, and adjust the belt tension. Refer to section 17 of the appropriate service manual. 6. Start the engine, turn the steering wheel from lock-to-lock, and check the power steering fluid level. Add fluid if necessary. 7. Make sure the power steering pump does not leak. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 98-023 > Mar > 98 > Power Steering Pump - Fluid Leak Power Steering Pump: All Technical Service Bulletins Power Steering Pump - Fluid Leak 98-023 March 9, 1998 Applies T0: 1994 - 97 Accord - ALL 1992 - 95 Civic - ALL 1995 - 96 Odyssey - ALL Leak From the Power Steering Pump SYMPTOM Fluid is leaking from the power steering pump between the pump housing and the cover. PROBABLE CAUSE The 0-ring between the pump housing and the cover is leaking. CORRECTIVE ACTION Replace the 0-ring between the pump housing and the cover. PARTS INFORMATION 0-ring (68.5 x 1.9 mm): P/N 91349-PY3-000, H/C 3676871 Genuine Honda Power Steering Fluid: P/N 08206-9002, H/C 3747284 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation number: 512711 Flat rate time: 0.8 hour Failed part: P/N 91349-PY3-000 H/C 3676871 Defect code: 060 Contention code: B06 Template ID: 98-023A Skill level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Remove the power steering pump. Refer to section 17 of the appropriate Service Manual. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 98-023 > Mar > 98 > Power Steering Pump - Fluid Leak > Page 7113 2. Remove the fours bolts that secure the pump cover to the pump housing, and remove the cover. 3. Remove the old 0-ring. Coat a new 0-ring with clean power steering fluid, and install the new 0-ring onto the pump cover. 4. Align the rollers with the holes in the pump cover, and install the cover. Torque the four mounting bolts to 20 N.m (14 lb-ft). 5. Reinstall the power steering pump, and adjust the belt tension. Refer to section 17 of the appropriate service manual. 6. Start the engine, turn the steering wheel from lock-to-lock, and check the power steering fluid level. Add fluid if necessary. 7. Make sure the power steering pump does not leak. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Page 7114 Power Steering Pump: Specifications Air Conditioning Deflection, Inches [01]: New ..................................................................................................................................................... .................................................... 0.20-0.28 Used ............................................................................... ......................................................................................................................... 0.26-0.41 Alternator Deflection, Inches [01]: New ..................................................................................................................................................... .................................................... 0.22-0.31 Used ............................................................................... ......................................................................................................................... 0.28-0.41 Power Steering Deflection, Inches [01]: New ..................................................................................................................................................... .................................................... 0.24-0.37 Used ............................................................................... ......................................................................................................................... 0.31-0.47 [01] -- Measured using 22 ft. lbs. force. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation Power Steering Pump: Service and Repair Removal and Installation 1. Drain power steering fluid from reservoir. 2. Loosen power steering pump adjusting bolt, mounting bolts and nuts, then remove power steering belt. 3. Cover alternator with shop towels to prevent damage from spilled power steering fluid, then disconnect inlet and outlet hoses from power steering pump and plug hoses. Take care not to spill fluid on body or parts. Wipe off any spilled fluid at once. Fig. 6 Power Steering Pump Removal 4. Remove power steering pump mounting bolt, then remove power steering pump, Fig. 6. Do not turn steering wheel with pump removed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 7117 Power Steering Pump: Service and Repair Disassembly After Removal . Remove power steering pump. 2. Drain steering fluid from pump, then place pump in a suitable vise and remove pulley and nut using holder tool No. 07725-0030000, or equivalent. Fig. 20 Exploded View Of Poweering Steering Pump 3. Remove control valve cover and bolts, Fig. 20, then remove spring, control valve and O-rings. 4. Inspect valve operation as follows: a. Inspect valve and valve bore for wear and damage, then slip valve back into housing and ensure valve moves in smoothly. If valve is damaged or movement is rough, then replace valve. b. Attach a hose to end of valve and submerge into power steering fluid, then blow air in the hose. If air bubbles leak through at less than 14.2 psi, then replace valve. c. Replacement valves must fit precisely into bore and must have same identification mark as old valve. 5. Remove inlet joint and O-ring, then remove pump cover and O-ring. 6. Remove pump cam ring from pump housing, then remove pump rotor and vanes. Replace pump as an assembly if pump cam ring, pump rotor or rotor vanes are defective. 7. Remove two rollers from side plate, then remove side plate, spring and O-rings. Replace pump as an assembly if side plate is defective. 8. Remove circlip, then remove drive shaft assembly from pump housing using a suitable plastic hammer. Pump components are aluminum and easily damaged. 9. Remove seal spacer and oil seal. 10. Inspect pump housing for damage on sealing surfaces. 11. Inspect bearing by rotating outer race slowly. If any play or roughness is felt, replace bearing using hub replacement tool No. 07GAF-SD40700, or equivalent. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 7118 Power Steering Pump: Service and Repair Assembly 1. Coat oil seal with steering grease, then install oil seal and seal spacer by hand. 2. Install drive shaft assembly using driver attachment tool No. 07947-6340500, or equivalent, then install circlip with tapered side facing up. 3. Coat side plate grooves with power steering fluid, then place O-rings on side plate. 4. Install preload spring into housing, then place 4.5 × 49.8 mm roller in 4.5 mm hole of pump housing. 5. Install side plate over roller and onto housing, then place 5 × 26.8 mm roller in 5 mm hole of side plate. 6. Install rotor to drive shaft with degrees mark facing up, then place vanes in rotor. Vanes must be installed with rounded end in contact with sliding surface of cam ring. 7. Install cam ring over rollers with degrees mark facing up, then apply clean power steering fluid to cam ring and vanes. 8. Install O-ring on pump cover, then align rollers with pump cover roller set holes. 9. Align projection on pump hosing with projection on pump cover, then install cover and tighten bolts to specification. 10. Install O-ring onto inlet joint, then install inlet joint to housing. 11. Coat O-rings and control valve with P/S fluid, then install O-ring into housing groves and control valve, spring and control valve cover onto housing. Tighten bolts to specification. 12. Place pump in suitable vise, then install pulley and nut. 13. Using holder tool No. 07725-0030000, or equivalent, tighten nut to specification. 14. Turn pulley and inspect pump for proper operation. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations Power Steering Pressure Switch: Locations Center Rear Of Engine Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 7123 Power Steering Pressure Switch: Diagrams For Connector Views refer to "Powertrain Management : Diagrams". Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 7124 Power Steering Pressure Switch: Description and Operation PURPOSE This signals the Engine Control Module (ECM) when the Power Steering load is high. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 7125 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Specifications Air Bag(s) Arming and Disarming: Specifications Component .......................................................................................................................................... ....................................................... Torque/Ft. Lbs. Dash Sensor Mounting Bolts .............................. .............................................................................................................................................................. .. 16 Driver Side Air Bag Assembly To Steering Wheel Bolts ................................................................................................................................................. 7.2 Passenger Side Air Bag Mounting Nuts & Bolts .................................................................................. ............................................................................. 7.2 SRS Unit Mounting Bolts ................................. .............................................................................................................................................................. .. 7.2 Steering Wheel To Column Steering Shaft Nut .......................................................................... ....................................................................................... 36 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Specifications > Page 7130 Air Bag(s) Arming and Disarming: Service Precautions 1. On models with 3-P SRS connectors, install red short connectors on air bags prior to disconnecting any part of SRS wiring harness. 2-P SRS connectors automatically short when disconnected. 2. Always use test harnesses. Do not use test probes directly on component connector pins or wires. 3. When connecting any test harnesses, push connectors straight in until secure. Do not bend connector pins. 4. Always keep red short connector on air bag connector when harness is disconnected. 5. Always store air bag assembly with pad surface facing upward. 6. Do not attempt to disassemble air bag assembly. 7. An air bag that has been deployed cannot be repaired or reused. 8. Keep air bag assembly free of oil and grease. 9. Do not expose air bag assembly to temperatures above 212°F. 10. Do not use SRS components from another vehicle. Always install new replacement components. 11. Do not paint air bag assembly to correct cosmetic flaws. It must be replaced. 12. Inspect all components prior to installation. Do not install any that appear to have been improperly handled or stored or that show any signs of damage. 13. When repairing vehicle, system should be disarmed as outlined under Technician Safety Information. 14. When performing service procedures, do not expose sensors or wiring or other SRS components to heat guns, welding or spray guns. 15. SRS wiring should not be spliced, soldered or repaired. 16. Use only special digital multimeter tool No. KS-AHM-32-003, or equivalent, digital multimeter with 0.0 mA or smaller output when switched to lowest ohmmeter range to inspect system. Analog or testers with higher outputs can damage circuits or cause accidental air bag deployment and, if equipped, seat belt pretensioner activation. 17. Do not bump SRS unit whenever ignition is turned On, or has been Off for less than three minutes. Unwanted deployment could result. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Specifications > Page 7131 Air Bag(s) Arming and Disarming: Service and Repair The Supplemental Restraint System (SRS) must be disarmed prior to disconnecting any electrical connectors or servicing any system components or items located near SRS electrical connectors. SRS electrical wiring can be identified by its yellow outer protective coating. To disarm the SRS, proceed as follows: 1. Obtain five-digit radio theft protection code number. 2. Disconnect battery ground cable, then the positive cable. Fig. 1 Driver Air Bag Disarming 3. After disconnecting cables, wait at least three minutes with ignition turned Off before disconnecting any SRS electrical connectors. This will allow air bag system back-up circuit capacitor to discharge. 4. Remove steering wheel access panel and disconnect electrical connector located between air bag and cable reel, Fig. 1 5. Remove glove compartment and access panel. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Specifications > Page 7132 Fig. 4 Passenger Air Bag Disarming 6. Disconnect front passenger air bag 3-P connector from SRS main harness and connect red short connector, Fig. 4. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Specifications > Page 7133 Fig. 12 Fuse Panel/SRS Connector 7. Using thin blade screwdriver, lift SRS to under-instrument panel fuse connector lid, Fig. 12, then press tab down and slide connector out. 8. Reverse procedure to reactivate system, noting following: a. Slide harness electrical connector onto fuse panel connections until it clicks, then close connector lid. b. Ensure all red short connectors have been removed and placed in their holders. c. Prior to connecting battery ground and positive cables, ensure all supplemental restraint system electrical connectors have been properly connected. d. After battery cables have been connected, turn ignition switch to On position. SRS indicator lamp should light for approximately six seconds. If lamp does not light or remains on longer than six seconds, A SYSTEM MALFUNCTION IS INDICATED. Refer to Testing and Inspection / Procedures See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview e. Turn radio control to On. When word Code appears on display panel, enter five-digit theft protection code number. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Description and Operation Key Reminder Switch: Description and Operation Battery voltage is supplied at all times to the seat belt reminder/key-ON beeper circuit in the integrated control unit. When you turn ON the ignition key switch the integrated control unit senses ground. If you open the driver's door, the door switch closes, causing the beeper to sound until the door is closed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Locations Steering Column Lock: Locations Right Side Of Steering Column Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service Precautions Steering Gear: Service Precautions WARNING: - To avoid rendering the SRS inoperative, which could lead to personal injury or death in the event of severe frontal collision, all SRS service work must be performed by an authorized mechanic. - Improper service procedures, including incorrect removal and installation of the SRS, could lead to personal injury caused by unintentional activation of the air bags. - Do not bump the SRS unit. Otherwise, the system may fail in cause of a collision, or the ai bags may deploy when the ignition switch is ON (II). - All SRS electrical wiring harnesses are covered with yellow insulation. Related components are located in the steering column, front console, dashboard lower panel, and in the dashboard above the glove box. Do not use electrical test equipment on these circuits. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Power Steering Steering Gear: Service and Repair Power Steering Removal 1. Using solvent and brush wash any oil and dirt off the valve body and its lines. Blow dry with compressed air. 2. Raise the power steering reservoir and disconnect the hose that goes to the oil cooler. 3. Connect a hose of suitable diameter to the disconnected hose that goes to the oil cooler and put the hose end in a suitable container. Caution: Clean up any spilled power steering fluid immediately. 4. Start engine and let idle. Turn the steering wheel from lock to lock several times. 5. When fluid stops running out of the hose, shut off the engine. Discard the old fluid. 6. Refit the return hose on the reservoir. 7. Raise front of vehicle and secure on jack stands. 8. Remove the front wheels. 9. Remove the steering joint cover. 10. Lock the steering shaft to stop the shaft from turning. Loosen the upper steering joint bolt and remove the lower steering join bolt. Move the joint toward the column. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Power Steering > Page 7145 11. Remove the shift cable holder. 12. Remove the cable bracket and disconnect the shift cable from the shift control shaft. 13. Remove the self-locking nuts and separate the three way catalytic converter. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Power Steering > Page 7146 14. Remove the cotter pin and castle nut. Install the 10mm hex nut on the ball joint. 15. Once the hex nut is flush with the ball joint pin end, use SST # 07MAC-SL00200 or equivalent and separate the tie-rod ball joint and knuckle. Caution: Take care not to damage the ball joint dust boot. 16. Disconnect the three lines from the valve body unit on the steering gearbox and immediately seal the hoses AND pipes to prevent contamination. 17. Remove the left tie-rod end, then slide the rack all the way to the right. 18. Remove the steering gearbox mounting bolts. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Power Steering > Page 7147 19. Pull the steering gearbox down to clear the pinion shaft from the bulkhead and remove the pinion shaft grommet. 20. Move the steering gearbox to the right so the left rack and clears the rear beam. 21. Hold the steering gearbox and slide the rack all the way to the left, place the left rack end below the rear beam. 22. Move the steering gearbox to the left and tilt the left side down and remove it from the car. Installation 1. Slide the rack all the way to the right. 2. Pass the right side of the steering gearbox above and through the right side of the rear beam. 3. Raise the left side of the steering gearbox above and through the left side of the rear beam. 4. Hold the steering gearbox and center the rack with its strokes. 5. Install the pinion shaft grommet and insert the pinion shaft up through the bulkhead. 6. Install and tighten the gearbox mounting bolts. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Power Steering > Page 7148 7. Connect the fluid lines to the valve body unit. 8. Reconnect the tie-rod ends to the steering knuckles, tighten the castle nut to the specified torque, and install new cotter pins. CAUTION: Torque the castle nut to the lower torque specification, then tighten it only far enough to align the slot with the pin hole. Do not align the nut by loosening. 9. Install the three way catalytic converter with the new gaskets and new self-locking nuts. 10. Connect the shift linkage. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Power Steering > Page 7149 Manual transmission model: - Connect the shift rod to the transmission and drive the spring pin with a punch, then install the pin retainer. Be sure that the projection on the pin retainer is in the hole. - Install the extension rod on the transmission case. Automatic transmission model: - Connect the shift cable end to the shift control shaft, and install the cable bracket. - Install the cable holder. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Power Steering > Page 7150 11. Center the steering rack with its strokes. 12. Make sure that the cable reel of the SRS is centered as follows: - Turn the steering wheel left approx. 1 50 degrees, and check the cable reel position. - If the cable reel is centered, the yellow gear tooth lines up with the alignment mark on the cover. - Return the steering wheel right approx. 1 50 degrees to the straight ahead position. 13. Slip the lower end of the steering joint onto the pinion shaft (line up the bolt hole with the groove around the shaft) and tighten the steering joint bolts. NOTE: Connect the steering shaft and pinion with the cable reel and steering rack centered. - Be sure that the lower steering joint bolt is securely in the groove in the steering gearbox pinion. - If the steering wheel and rack are not centered, reposition the serrations at the lower end of the steering joint. 14. Install the steering joint cover with the clamps and clip. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Power Steering > Page 7151 15. Fill the system with recommended power steering fluid and bleed air from the system 16. After installation, perform the following checks. - Check the gearbox for leaks. - Adjust the front toe. - Check the steering wheel spoke angle. Adjust by turning the right and left tie-rods, if necessary. NOTE: Turn the right and left tie-rods equally. Steering Gear Disassembly 1. Remove control valve unit from steering gear as outlined previously. 2. Carefully clamp gear into vise with soft jaws. Fig. 3 Exploded View Of Steering Gear 3. Remove tie rod assembly, then the boot band and tube clamps, Fig. 3. 4. Pull dust seals away from ends of gearbox. 5. Hold steering rack with 19 mm wrench and unscrew rack end with wrench. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Power Steering > Page 7152 6. Push right end of rack back into cylinder housing so smooth surface that rides against seal will not be damaged. 7. Loosen rack screw locknut and remove rack guide screw. 8. Remove spring and rack guide from gear housing. 9. Remove circlip, then the steering pinion assembly. 10. Remove four cylinder housing to gear attaching bolts, then slide housing off rack. 11. Remove O-ring, back-up ring, steering rack bushing A and cylinder spring. 12. Remove cylinder end seal from cylinder housing. 13. Remove cylinder seal retainer, cylinder cap and steering rack from gear housing. 14. Remove retainer washer from gear housing. 15. Check pinion holder for excessive play or rough movement. If there is excessive play or any rough movement, replace bearing as follows: a. Remove gear housing cap from gear housing. b. Remove circlip from pinion holder, then the pinion holder from gear housing. c. Check needle roller bearings in pinion holder and gear housing for any damage. If needle bearings are satisfactory, pack with grease. If needle bearings show damage, replace as a set. d. Remove pinion lower ball bearing from gear housing. e. Using bearing installation tool No. 07746-0010300, or equivalent, and a hammer, drive new pinion lower ball bearing into gear housing. f. Install pinion holder into gear housing, then the circlip with its tapered side facing out. g. Grease O-ring, then install it in groove of gear housing cap. h. Install gear housing cap. 16. Remove cylinder and seal retainer from steering rack. 17. Remove O-ring, circlip and cylinder cap from seal retainer. 18. Remove O-rings from cylinder cap, then the bushing stopper ring from seal retainer. 19. Remove cylinder end seal, then carefully pry piston seal ring and O-ring off rack. Steering Gear Assembly 1. Install new O-ring on rack. 2. Coat piston seal ring guide with power steering fluid and slide onto rack, large end first. Fig. 4 Piston Seal Ring Installation 3. Position new piston seal ring onto piston seal ring guide tool No. 07GAG-SD40100, or equivalent. Slide seal ring down to large end of tool and Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Power Steering > Page 7153 pull it off into piston groove on top of O-ring, Fig. 4. 4. Coat piston seal ring and inside of special tool with power steering fluid, then carefully slide tool onto rack and over piston ring. 5. Rotate tool as you move it up and down to seat piston seal ring. 6. Coat new O-rings with grease and install on cylinder cap. 7. Slide cylinder cap onto seal retainer, then install circlip and O-ring on seal retainer. 8. Grease sliding surface of steering rack bushing B and install bushing on steering rack with groove of bushing facing steering rack piston. 9. Grease sliding surfaces of new cylinder end seal and seal slider tool No. 07GAG-SD40300, or equivalent, then place seal on tool with its grooved side facing opposite slider. 10. Grease steering rack and install tool. Ensure rack teeth do not face slot in tool. 11. Separate cylinder end seal from tool, then remove tool from rack. 12. Fit seal retainer on steering rack, then push rack bushing B toward seal retainer until cylinder end seal is seated in retainer. 13. Fit seal stopper ring in groove of seal retainer securely, then grease steering rack. 14. Install retainer washer on gear housing. 15. Place gear housing on work bench and insert seal retainer and steering rack into gear housing. 16. Coat inside of cylinder with power steering fluid, then slide it over rack and into gear housing until it seats. 17. Install cylinder spring over rack, then coat rack bushing A with power steering fluid and install it on spring. 18. Install piston seal ring guide tool No. 07GAG-SD40400, or equivalent, or vinyl tape onto end of steering rack and coat with grease. 19. Coat inside surface of cylinder with power steering fluid and install cylinder end seal with its grooved side facing out. 20. Install O-ring and back-up ring on gear housing. 21. Carefully position cylinder housing on gear housing and loosely install using four bolts. Be careful not to damage end seal in cylinder housing. 22. Remove vinyl tape or special tool from end of steering rack. 23. While pushing cylinder housing and gear housing together, tighten to specifications. 24. Install steering pinion in pinion holder, then the circlip with its tapered side facing out, securely into pinion holder groove. 25. Install O-ring onto rack guide screw, then coat rack guide with grease. 26. Install rack guide, spring and rack guide screw on gear housing. 27. Tighten rack guide screw until it compresses spring and seats against rack guide, then loosen it. 28. Tighten screw to specifications, then back it off approximately 20 degrees. 29. Install locknut on rack guide screw. While holding rack guide screw in position, tighten locknut to specifications. 30. Install valve body unit. 31. Install new lock washer in groove of steering rack. 32. Holding steering rack with a wrench, tighten to specifications. 33. Stake four sections of lock washer using suitable drift. 34. Apply steering grease to circumference of rack end housing, then coat rack end groove with suitable silicone grease. 35. Install boots with tube clamps on rack ends. 36. Install boot bands and bend both ends of locking tabs. Turn rack from left to right to ensure boots do not twist or bind. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Power Steering > Page 7154 Steering Gear: Service and Repair Manual Steering Removal and Installation NOTE: On Air Bag Equipped Models, disable airbag system as outlined under Technician Safety Information. On vehicles equipped with coded theft protection system, refer to Vehicle Damage Warnings for disarming procedures. 1. Raise and support front of vehicle, then remove front wheels. 2. Remove steering joint cover. 3. Loosen upper steering joint bolt and remove lower steering joint bolt, then move joint toward column. Lock steering shaft with ignition key to retain steering shaft in position. 4. On models equipped with manual transaxle, proceed as follows: a. Remove shift extension from transaxle case. b. Slide boot back at connecting position of gear shift rod. c. Remove pin retainer and drive out spring pin with punch, then disconnect shift rod. 5. On models equipped with automatic transaxle, proceed as follows: a. Remove shift cable holder, then the cable bracket. b. Disconnect shift cable from shift control shaft. 6. Separate three way catalytic converter by removing self-locking nuts. 7. Separate tie rod ball joint and knuckle using ball joint remover tool No. 07MAC-SL00200, or equivalent. 8. Remove left tie rod end, then slide rack completely to right. 9. Remove gearbox mounting bolts, then pull gearbox all the way down to clear pinion shaft from bulkhead. 10. Remove pinion shaft grommet, then move gearbox to right so left rack end clears rear beam. 11. Hold gearbox and slide rack completely to left, then place left rack end below rear beam. 12. Move gearbox to left and tilt left side down to remove from vehicle. 13. Reve4rse procedures to install, and tighten fasteners to specifications. 14. Rearm airbag system as outlined under Technician Safety Information. 15. Rearm radio coded theft protection system as outlined under Vehicle Damage Warnings. Fig. 5 Rack Guide Screw Adjustment 13. Reverse procedure to install. If necessary, adjust rack guide as follows: a. Loosen rack guide locknut with suitable tool, Fig. 5. b. Tighten guide screw until it compresses spring and lightly seats against guide, then loosen screw. c. Tighten screw to specifications, then back screw off approximately 1/12 turn (30 degrees). d. Hold position of adjusting screw and tighten locknut to specifications. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Power Steering > Page 7155 Disassembly Before disassembling the steering gear, clean gear thoroughly to prevent dirt from entering the unit. During disassemble, carefully note and label components removed from the main gear unit for reference during assembly. 1. Clamp steering gear in vise, then remove tie rod end and locknut. 2. Remove boot bands and tube clamps, then pull boots away from ends of gearbox. 3. Hold rack with suitable wrench and remove rack end. 4. Remove rack locknut and guide screw, then rack guide spring and guide from steering gear. 5. Remove pinion boot and dust seal. 6. Remove 35 mm snap ring securing pinion, then withdraw pinion and bearing assembly. 7. Remove rack, then the rack end bushings from housing. 8. If necessary, use sharp knife to cut down length of gearbox mounting cushion, then remove cushion. Use care not to damage paint on cylinder housing. Assembly 1. Install gearbox mounting cushion as follows: a. Apply weatherstrip adhesive to inside of new cushion. b. Install and position 0.80 inch from end of cylinder housing. After installing cushion, wipe off any excess adhesive that may have dripped inside cylinder housing. c. Apply thin coat of grease to inside of rack end bushing. Do not fill bushing slots with grease as they must remain open to serve as air passages. 2. Install rack end bushings, aligning round projections on bushings with holes in housing. 3. Install steering into cylinder housing. 4. Drive steering pinion shaft into gear housing using suitable tools. 5. Install snap rings and seals. 6. Install rack guide and spring, then the guide screw and locknut. Install new lock washer in groove on steering rack. 7. Hold steering rack with wrench and tighten rack end to specifications. 8. Stake four sections of lock washer with suitable roll pin drift and mallet. 9. Apply grease to circumference of rack end housing, then coat rack end groove and inside of boot with silicone grease. 10. Install boots in rack end with tube clamps. 11. Install boot band with rack in straight-ahead position (right and left tie rods are equal in length). Tabs should face up and slightly forward. 12. Install new boot bands on boot and bend both sets of locking tabs, then lightly tap on doubled-over portions to reduce their height. 13. Slide rack right and left to be certain boots are not deformed or twisted, then install right and left tie rod end on right and left rack end. 14. Install steering gear and tighten fasteners to specifications. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service Precautions > Airbag Handling and Storage Steering Wheel: Service Precautions Airbag Handling and Storage Do not disassemble the airbags. it has no serviceable parts. Once an airbag has been deployed, it cannot be repaired or reused. For temporary storage of the airbag during service, please observe the following precautions. WARNING: If the airbag is improperly stored face down, accidental deployment could propel the unit with enough force to cause serious injury. Store the removed airbag with the pad surface up. Never put any things on the removed airbag. Keep free from any oil, grease, detergent, or water to prevent damage to the airbag. Store the removed airbag on a secure, flat surface away from any high heat source (exceeding 200° F / 93° C). Never perform electrical inspections to the airbags, such as measuring resistance Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service Precautions > Airbag Handling and Storage > Page 7160 Do not position yourself in front of the airbag assembly during removal, inspection, or replacement. CAUTION: Improper handling or storage can internally damage the airbag assembly, making it inoperative. If you suspect the airbag assembly has been damaged, install a new unit, and refer to the Deployment/Disposal Procedures (see "Damaged Airbag Special Procedure") for disposing of the damaged airbag. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service Precautions > Airbag Handling and Storage > Page 7161 Steering Wheel: Service Precautions Deployed Air Bag Put on a pair of shop gloves and safety glasses to protect your hands and eyes from possible irritation and heat when handling the deployed air bag assembly. Driver Airbag Assembly After the air bag assembly has been deployed, the surface of the air bag may contain a powdery residue. This powder consists primarily of cornstarch (used to lubricate the bag as it inflates) and by products of the chemical reaction. Sodium hydroxide dust (similar to lye soap) is produced as a by product of the deployment reaction. The sodium hydroxide then quickly reacts with atmospheric moisture and is converted to sodium carbonate and sodium bicarbonate (baking soda). Therefore, it is unlikely that sodium hydroxide will be present after deployment. Passenger Airbag Assembly The passenger inflator requires no special precaution after deployment. 95% of the particulate emission are potassium chloride (KCL), which is commonly sold as an edible salt-substitutes. even if water is applied. Post deployment products are relatively pH neutral. Disposing the inflator by burying it in a landfill will not products any hazardous products. As with any dusty environment, safety goggles, dust mask and gloves should be worn. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service Precautions > Airbag Handling and Storage > Page 7162 Steering Wheel: Service Precautions Undeployed Air Bag During the course of a vehicle's useful life, certain situations may arise which will necessitate the disposal of a live (undeployed) air bag assembly. This information covers proper procedures for disposing of a live air bag assembly. Before a live air bag assembly can be disposed of, it must be deployed. A live air bag assembly must not be disposed of through normal refuse channels. Special care is necessary when handling and storing a live (undeployed) air bag assembly. The rapid gas generation produced during deployment of the air bag could cause the air bag assembly, or an object in front of the air bag assembly, to be thrown through the air in the unlikely event of an accidental deployment. WARNING: FAILURE TO FOLLOW PROPER SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AIR BAG ASSEMBLY DISPOSAL PROCEDURES CAN RESULT IN AIR BAG DEPLOYMENT WHICH MAY CAUSE PERSONAL INJURY. AN UNDEPLOYED AIR BAG ASSEMBLY MUST NOT BE DISPOSED OF THROUGH NORMAL REFUSE CHANNELS. THE UNDEPLOYED AIR BAG ASSEMBLY CONTAINS SUBSTANCES THAT CAN CAUSE SEVERE ILLNESS OR PERSONAL INJURY IF THE SEALED CONTAINER IS DAMAGED DURING DISPOSAL. DISPOSAL IN ANY MANNER INCONSISTENT WITH PROPER PROCEDURES MAY BE A VIOLATION OF FEDERAL, STATE, AND / OR LOCAL LAW. In situations which require deployment of a live air bag assembly, deployment may be accomplished inside or outside the vehicle. The method employed Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service Precautions > Airbag Handling and Storage > Page 7163 depends upon the final disposition of the particular vehicle, as noted in "Deployment Outside Vehicle" and "Deployment Inside Vehicle". WARNING: WHEN CARRYING A LIVE AIR BAG ASSEMBLY, MAKE SURE THE BAG OPENING IS POINTED AWAY FROM YOU. IN CASE OF AN ACCIDENTAL DEPLOYMENT, THE BAG WILL THEN DEPLOY WITH MINIMAL CHANCE OF INJURY. NEVER CARRY THE AIR BAG ASSEMBLY BY THE WIRES OR CONNECTOR ON THE UNDERSIDE OF THE MODULE. Handling/Installation/Diagnosis 1. Air bag assembly should not be subjected to temperatures above 65° C (150° F). 2. Air bag assembly, and SDM should not be used if they have been dropped from a height of 100 centimeters (3.28 feet) or more. 3. When a SDM is replaced, it must be oriented with the arrow on the SDM pointing toward the front of the vehicle. It is very important for the SDM to be located flat on the mounting surface, parallel to the vehicle datum line. It is important that the SDM mounting surface is free of any dirt or other foreign material. 4. Do not apply power to the SRS unless all components are connected or a diagnostic chart requests it, as this will set a diagnostic trouble code. 5. The "SRS Diagnostic System Check" must be the starting point of any SRS diagnostics. The "SRS Diagnostic System Check" will verify proper "AIR BAG" warning lamp operation and will lead you to the correct chart to diagnose any SRS malfunctions. Bypassing these procedures may result in extended diagnostic time, incorrect diagnosis, and incorrect parts replacements. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair > Removal Steering Wheel: Service and Repair Removal 1. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. 2. Remove air bag assembly as follows: a. Remove mounting screw covers. b. Remove mounting screws using T30 Torx bit. c. Disconnect electrical connectors, then remove air bag assembly. When storing a removed air bag assembly, ensure pad is facing upward. 3. On models less air bag, remove steering wheel emblem. 4. Ensure steering wheel is in a straight ahead position, then remove steering shaft nut or bolt. 5. Remove steering wheel by rocking it from side to side while pulling steadily with both hands. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair > Removal > Page 7166 Steering Wheel: Service and Repair Installation 1. On models equipped with air bag, center the cable reel as follows: a. Rotate cable reel clockwise until it stops. b. Rotate cable reel counterclockwise (approximately two turns) until yellow gear tooth lines up with alignment mark on cover, or arrow mark on cable reel label points straight up. 2. Install steering wheel on steering shaft in straight ahead position. Fig. 1 Steering Wheel Installation. Models W/air Bag 3. On models equipped with air bag, ensure steering wheel shaft engages pins of cable reel, Fig. 1. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair > Removal > Page 7167 Fig. 2 Steering Wheel Installation. Models Less Air Bag 4. On models less air bag, align slots on steering wheel and tabs on turn signal cancelling sleeve, Fig. 2. 5. torque steering wheel mounting nut to 36 ft. lbs. 6. On models equipped with air bag, install air bag assembly with new Torx bolts. Confirm air bag assembly is securely attached to steering wheel; otherwise, severe personal injury could result during later air bag deployment. 7. On models less air bag, install steering column center pad. 8. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications Ball Joint: Specifications Component .......................................................................................................................................... .......................................................... Torque/Ft. Lbs. Lower Ball Joint Castle Nut ............................. .............................................................................................................................................................. .... 40 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Page 7172 Ball Joint: Testing and Inspection 1. Raise and support vehicle. 2. Grasp tire at top and bottom. 3. Shake tire back and forth, check for any side to side movement in ball joint. 4. Replace ball joint if there is any side to side movement. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Page 7173 Ball Joint: Service and Repair 1. Remove steering knuckle as described under Steering Knuckle /Service and Repair. 2. Remove lower ball joint dust cover snap ring, then the dust boot. 3. Remove ball joint snap ring. 4. Use ball joint replacement tool No. 07MAC-SC0020 and ball joint removal base tool No. 07965-SB00100, or equivalents, to press ball joint out of steering knuckle. 5. Press replacement ball joint into steering knuckle by hand. 6. Press ball joint into steering knuckle using ball joint replacement tool No. 07MAC-SC0020 and ball joint installation base tool No.07965-SB00200, or equivalents. 7. Install ball joint snap ring. 8. Install dust cover and snap ring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair Front Steering Knuckle: Service and Repair 1. Raise and support front of vehicle, then remove front wheels. 2. Raise spindle nut locking tab, then remove spindle nut. 3. Remove brake hose bracket mounting bolts. 4. Remove caliper and position aside. Do not allow caliper assembly to hang from brake hose. 5. Remove brake disc attaching screws, then thread two 8 x 1.25 x 12 mm bolts into attaching screw holes to push disc from hub. When tightening screws, turn only two turns at a time to prevent excessively cocking the brake disc. 6. Remove brake disc from knuckle. 7. Remove speed sensor wire bracket, then the speed sensor from knuckle. 8. Remove tie rod end cotter pin and nut. 9. Remove tie rod end using suitable tie rod end remover. 10. Remove lower ball joint cotter pin, then loosen ball joint nut half way. 11. Using ball joint remover tool No. 07MAC-SL00200, or equivalent, separate ball joint and lower arm. 12. Remove upper ball joint shield, then the cotter pin and nut. 13. Separate upper ball joint from upper arm using suitable ball joint remover. 14. Remove steering knuckle and hub assembly by sliding off driveshaft. 15. Remove hub from steering knuckle using suitable press. 16. Remove knuckle ring, circlip and splash guard from knuckle. 17. Press out wheel bearing from hub using driver tool No. 07749-0010000, attachment tool No. 07746-0010500 and base tool No. 07GAF-SE00401, or equivalents. 18. Remove outboard bearing inner race from hub. Fig. 4 Front Suspension 19. Reverse procedure to install. Refer to Fig. 2 for tightening specifications. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Strut Suspension Strut / Shock Absorber: Service and Repair Front Strut 1. Raise and support front of vehicle and remove wheels. 2. Remove brake hose mounting bolts from damper. Fig. 4 Front Suspension 3. Remove damper fork pinch bolt, fork retaining bolt and the damper fork, Fig. 4. 4. Remove upper strut base mounting nuts and the strut assembly. 5. Insert upper base studs through mounting holes, ensuring alignment tab on shock body faces toward inside, then install base mounting nuts hand tight. 6. Install damper fork over drive axle and lower arm, then slide fork over lower end of shock absorber, aligning tab on shock with slot in fork. 7. Install damper fork retaining bolt and pinch bolt hand tight. 8. Position suitable jack under knuckle hub, then raise knuckle until weight of vehicle is supported by damper assembly. 9. With weight of vehicle supported by damper, tighten damper fork retaining bolt, damper fork pinch bolt and shock absorber base nuts to specifications. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Strut > Page 7181 Suspension Strut / Shock Absorber: Service and Repair Rear Strut Removal Fig. 3 Exploded View Of Rear Damper Assembly 1. Raise and support rear of vehicle, then remove rear wheel(s) and place in luggage compartment for ballast. 2. Remove damper cap at rear seat lining. 3. Remove two flange attaching nuts and damper mounting bolt, then remove speed sensor. 4. Remove self-locking bolt connecting lower arm and trailing arm. If vehicle is raised with hoist, center of gravity may change, causing vehicle to tip forward when damper is removed. 5. Lower rear suspension and remove rear damper. 6. Using suitable spring compressor, compress damper spring enough to remove damper assembly self-locking nut. 7. Disassemble damper assembly, Fig. 3. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Strut > Page 7182 Installation 1. Mount damper assembly in spring compressor. Fig. 4 Damper Mounting Base Installation 2. Assemble rear damper in reverse order of removal except damper mounting washer and self-locking nut. Align bottom of damper spring and spring lower seat, Fig. 4. 3. Compress spring and install damper mounting washer and self-locking nut. 4. Loosely tighten self-locking nut, then, while holding damper shaft torque self-locking nut to 22 ft. lbs. 5. Lower rear suspension and position damper assembly in its original position. 6. Loosely install two flange nuts and speed sensor, then use suitable floor jack to raise rear suspension until weight of vehicle is on damper. 7. Install damper mounting bolt and self-locking bolt, then torque to 40 ft. lbs. Mounting bolt and self-locking bolt should be tightened with damper under vehicle load. 8. Tighten two flange attaching nuts, then install damper cap. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Trailing Arm Bushing > Component Information > Technical Service Bulletins > Customer Interest: > 00-006 > Mar > 06 > Suspension - Rear Suspension Clunk/Squeak On Bumps Trailing Arm Bushing: Customer Interest Suspension - Rear Suspension Clunk/Squeak On Bumps 00-006 March 31, 2006 Applies To: *1988-00 Civic - ALL 1997-01 CR-V-ALL 1993-97 Del Sol - ALL* Clunk or Squeak From Rear Suspension (Supersedes 00-006, dated December 11, 2001, to update the information marked by the black bars and asterisks) SYMPTOM A clunk or squeak from the rear suspension when going over rough or bumpy roads. PROBABLE CAUSE Broken rear trailing arm bushing(s). CORRECTIVE ACTION Replace the rear trailing arm bushing(s). PARTS INFORMATION *Rear Trailing Arm Bushing: 1988-00 Civic and 1993-97 Del Sol P/N 52385-SR3-000, H/C 4098299 1997-01 CR-V: P/N 52385-SR3-003, H/C 7424773 TOOL INFORMATION Trailing Arm Bushing Installation Set: T/N 07AAF-SK7A130, H/C 8283822 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: 1988-00 Civic and 1993-97 Del Sol: P/N 52385-SR3-000 H/C 4098299 1997-01 CR-V: P/N 52385-SR3-003 H/C 7424773 Defect Code: 01801 Symptom Code: 04205* Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Trailing Arm Bushing > Component Information > Technical Service Bulletins > Customer Interest: > 00-006 > Mar > 06 > Suspension - Rear Suspension Clunk/Squeak On Bumps > Page 7192 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE *NOTE: ISIS online service manual information is only available for vehicles 1990 and newer. 1. Remove the rear trailing arm: ^ Refer to the suspension section of the appropriate service manual, or ^ Online, enter keyword REAR SUSPENSION, then select Suspension Arms Replacement from the list.* 2. Mark the trailing arm at the arrow on the bottom of the bushing. 3. Place the arm on a hydraulic press, supported by the hub base, with the spindle facing up. 4. With the hub driver, press the old bushing out of the trailing arm. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Trailing Arm Bushing > Component Information > Technical Service Bulletins > Customer Interest: > 00-006 > Mar > 06 > Suspension - Rear Suspension Clunk/Squeak On Bumps > Page 7193 5. Install the new bushing with the short end toward the outside of the vehicle. Align the arrow with the mark you made on the trailing arm. 6. Press the new bushing into the trailing arm until its edge is 10 to 12 mm above the surface of the arm. 7. Reinstall the trailing arm. 8. If necessary, repeat steps 1 thru 7 to install a new bushing in the other rear trailing arm. 9. Bleed the brake system: * ^ Refer to the brakes section of the appropriate service manual, or ^ Online, enter keyword BLEED, then select Brake System Bleeding from the list. 10. Check the wheel alignment, and adjust it if needed: ^ Refer to the suspension section of the appropriate service manual, or ^ Online, enter keyword WHEEL ALIGNMENT, then select Wheel Alignment - Rear Toe Inspection/Adjustment from the list.* Disclaimer Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Trailing Arm Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-006 > Mar > 06 > Suspension - Rear Suspension Clunk/Squeak On Bumps Trailing Arm Bushing: All Technical Service Bulletins Suspension - Rear Suspension Clunk/Squeak On Bumps 00-006 March 31, 2006 Applies To: *1988-00 Civic - ALL 1997-01 CR-V-ALL 1993-97 Del Sol - ALL* Clunk or Squeak From Rear Suspension (Supersedes 00-006, dated December 11, 2001, to update the information marked by the black bars and asterisks) SYMPTOM A clunk or squeak from the rear suspension when going over rough or bumpy roads. PROBABLE CAUSE Broken rear trailing arm bushing(s). CORRECTIVE ACTION Replace the rear trailing arm bushing(s). PARTS INFORMATION *Rear Trailing Arm Bushing: 1988-00 Civic and 1993-97 Del Sol P/N 52385-SR3-000, H/C 4098299 1997-01 CR-V: P/N 52385-SR3-003, H/C 7424773 TOOL INFORMATION Trailing Arm Bushing Installation Set: T/N 07AAF-SK7A130, H/C 8283822 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: 1988-00 Civic and 1993-97 Del Sol: P/N 52385-SR3-000 H/C 4098299 1997-01 CR-V: P/N 52385-SR3-003 H/C 7424773 Defect Code: 01801 Symptom Code: 04205* Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Trailing Arm Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-006 > Mar > 06 > Suspension - Rear Suspension Clunk/Squeak On Bumps > Page 7199 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE *NOTE: ISIS online service manual information is only available for vehicles 1990 and newer. 1. Remove the rear trailing arm: ^ Refer to the suspension section of the appropriate service manual, or ^ Online, enter keyword REAR SUSPENSION, then select Suspension Arms Replacement from the list.* 2. Mark the trailing arm at the arrow on the bottom of the bushing. 3. Place the arm on a hydraulic press, supported by the hub base, with the spindle facing up. 4. With the hub driver, press the old bushing out of the trailing arm. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Trailing Arm Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-006 > Mar > 06 > Suspension - Rear Suspension Clunk/Squeak On Bumps > Page 7200 5. Install the new bushing with the short end toward the outside of the vehicle. Align the arrow with the mark you made on the trailing arm. 6. Press the new bushing into the trailing arm until its edge is 10 to 12 mm above the surface of the arm. 7. Reinstall the trailing arm. 8. If necessary, repeat steps 1 thru 7 to install a new bushing in the other rear trailing arm. 9. Bleed the brake system: * ^ Refer to the brakes section of the appropriate service manual, or ^ Online, enter keyword BLEED, then select Brake System Bleeding from the list. 10. Check the wheel alignment, and adjust it if needed: ^ Refer to the suspension section of the appropriate service manual, or ^ Online, enter keyword WHEEL ALIGNMENT, then select Wheel Alignment - Rear Toe Inspection/Adjustment from the list.* Disclaimer Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Trailing Arm Bushing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trailing Arm Bushing: > 93033 > Jun > 96 > Seat Belt - Tongue Stopper Button Broken Seat Belt: All Technical Service Bulletins Seat Belt - Tongue Stopper Button Broken Bulletin No. 93-033 Issue Date JUNE 3, 1996 Model: 1992 and Later [NEW] Applicable To: ALL except PASSPORT [NEW] File Under: BODY Broken Seat Belt Tongue Stopper Button (Supersedes 93-033, dated October 22, 1993) PROBLEM The seat belt tongue stopper button is broken, allowing the tongue to slide down to the floor. CORRECTIVE ACTION Install a new seat belt tongue stopper button listed under PARTS INFORMATION. 1. Slide the seat belt tongue up the seat belt past the tongue stopper button hole. Temporarily secure the seat belt tongue to the belt fabric with masking tape. 2. Insert the male section of the button through the hole in the belt fabric. Align and install the female section of the stopper to the male section. 3. Preset the closed gap on a pair of vise-grip pliers to 4.5 mm. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Trailing Arm Bushing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trailing Arm Bushing: > 93033 > Jun > 96 > Seat Belt - Tongue Stopper Button Broken > Page 7206 4. Place the flat portion of the jaws over the tongue stopper, and squeeze until the vise-grip jaws lock and deform the stopper shaft. PARTS INFORMATION Seat Belt Tongue Stopper: WARRANTY CLAIM INFORMATION Warranty Coverage: Seat belts that fail to function properly during normal use are covered under warranty for the useful life of the car. Warranty Does Not Cover: ^ Malfunction due to abuse, alteration, accidental damage or damage resulting from a collision or misuse. ^ Replacement of a properly functioning seat belt for cosmetic or comfort reasons. Operation number: 854125 Flat rate time: 0.2 hour (one or two sides) Failed part: P/N 04814-SM1-AO2ZA [NEW] H/C 3919289 Defect code: L18 Contention code: A02 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Trailing Arm Bushing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trailing Arm Bushing: > 93033 > Jun > 96 > Seat Belt - Tongue Stopper Button Broken > Page 7212 4. Place the flat portion of the jaws over the tongue stopper, and squeeze until the vise-grip jaws lock and deform the stopper shaft. PARTS INFORMATION Seat Belt Tongue Stopper: WARRANTY CLAIM INFORMATION Warranty Coverage: Seat belts that fail to function properly during normal use are covered under warranty for the useful life of the car. Warranty Does Not Cover: ^ Malfunction due to abuse, alteration, accidental damage or damage resulting from a collision or misuse. ^ Replacement of a properly functioning seat belt for cosmetic or comfort reasons. Operation number: 854125 Flat rate time: 0.2 hour (one or two sides) Failed part: P/N 04814-SM1-AO2ZA [NEW] H/C 3919289 Defect code: L18 Contention code: A02 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Adjustments Wheel Bearing: Adjustments Wheel bearings and hub on these models are an integral assembly and bearings cannot be adjusted. If hub endplay exceeds 0.002 inch with spindle nut properly tightened, hub and bearing assembly should be replaced. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension Wheel Bearing: Service and Repair Front Suspension 1. Raise and support front of vehicle, then remove front wheels. 2. Raise spindle nut locking tab, then remove spindle nut. 3. Remove brake hose bracket mounting bolts. 4. Remove caliper and position aside. Do not allow caliper assembly to hang from brake hose. 5. Remove brake disc attaching screws, then thread two 8 x 1.25 x 12 mm bolts into attaching screw holes to push disc from hub. When tightening screws, turn only two turns at a time to prevent excessively cocking the brake disc. 6. Remove brake disc from knuckle. 7. Remove speed sensor wire bracket, then the speed sensor from knuckle. 8. Remove tie rod end cotter pin and nut. 9. Remove tie rod end using suitable tie rod end remover. 10. Remove lower ball joint cotter pin, then loosen ball joint nut half way. 11. Using ball joint remover tool No. 07MAC-SL00200, or equivalent, separate ball joint and lower arm. 12. Remove upper ball joint shield, then the cotter pin and nut. 13. Separate upper ball joint from upper arm using suitable ball joint remover. 14. Remove steering knuckle and hub assembly by sliding off driveshaft. 15. Remove hub from steering knuckle using suitable press. 16. Remove knuckle ring, circlip and splash guard from knuckle. 17. Press out wheel bearing from hub using driver tool No. 07749-0010000, attachment tool No. 07746-0010500 and base tool No. 07GAF-SE00401, or equivalents. 18. Remove outboard bearing inner race from hub. Fig. 4 Front Suspension 19. Reverse procedure to install. Refer to Fig. 2 for tightening specifications. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 7218 Wheel Bearing: Service and Repair Rear Suspension Disc Brake Models 1. Raise and support vehicle, then remove rear wheels. 2. Apply parking brake, then remove hub cap. 3. Raise locking tab on spindle nut, then remove nut. 4. Remove 6 mm brake disc retaining screw, then the caliper shield. 5. Remove brake hose mounting bolts, then the caliper bracket mounting bolts. 6. Remove caliper and hang from undercarriage with short piece of wire. Do not hang caliper by brake hose. 7. Screw two 12 mm bolts into disc to push disc off of hub. Remove disc. 8. Remove hub unit from knuckle. 9. Reverse procedure to install. Drum Brake Models 1. Raise and support rear of vehicle, then remove wheel and brake drum. 2. Remove grease cap, spindle nut and washer. 3. Remove hub and bearing unit from spindle. 4. Reverse procedure to install. Tighten spindle nut to specifications, then stake shoulder of nut into groove in spindle. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Component .......................................................................................................................................... .......................................................... Torque/Ft. Lbs. Spindle Nut ...................................................... .............................................................................................................................................................. .. 134 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 94025 > Aug > 94 > Steering - Wheel Oscillates or Has a Shimmy Tires: Customer Interest Steering - Wheel Oscillates or Has a Shimmy Bulletin No. 94-025 Model ALL Applicable To ALL File Under SUSPENSION Issue Date AUG 22, 1994 Steering Wheel Shimmy SYMPTOM The steering wheel oscillates, or shimmies, when driving between 58 and 62 mph. It may be most noticeable on smooth roads, and may vary with slight steering inputs. PROBABLE CAUSE An imbalance of the wheel/tire/hub/disc assembly in the front end. CORRECTIVE ACTION Dynamically balance the wheel and tire assembly off the car. Then, if necessary, use the Hofmann Finish Wheel Balancer to balance the wheel/tire/hub/disc assembly on the car. 1. Drive the car on a smooth surface between 58 and 62 mph. Turn the steering wheel slightly, and allow the steering to self-center. Repeat this several times and observe the steering wheel motion. If the steering wheel does not oscillate, or the movement is different than shown below, the car does not have an imbalance problem. Do not continue with this procedure. If the steering wheel oscillates as shown, continue with this procedure. 2. Dynamically balance all four wheel/tire assemblies off the car. Make sure the balancer is capable of balancing to an accuracy of within 5 grams. Use only Honda wheel weights (see PARTS INFORMATION). NOTE: To verify the balancer's accuracy and calibration, refer to the DYNAMIC OFF-CAR WHEEL BALANCER CALIBRATION CHECK. 3. Reinstall the balanced wheel/tire assemblies and torque the wheel nuts to 80 lb.ft. Do not use an impact wrench to snug up or torque the wheel nuts; it may damage or distort the wheel and cause steering wheel oscillation. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 94025 > Aug > 94 > Steering - Wheel Oscillates or Has a Shimmy > Page 7232 4. Road test the car and check for steering wheel oscillation. If it still oscillates, use the Hofmann Finish Wheel Balancer to do a finish balance on the front wheel/tire/hub/disc assemblies. NOTE: Refer to section 4 of the Hofmann DAFB-10 Finish Wheel Balancer Operator's Manual that came with the unit for detailed instructions. DYNAMIC OFF-CAR WHEEL BALANCER CALIBRATION CHECK Use this procedure to determine if the balancer is accurate to within 5 grams of imbalance. If the balancer is not accurate to within 5 grams, it must be calibrated or repaired before being used to correct a steering wheel oscillation problem. You will need a Honda factory or accessory alloy wheel only, with no tire mounted, to perform this procedure. 1. Before starting, make sure the wheel has no balance weights. Perform a static balance, adding weights as necessary to only one side of the wheel. 2. Loosen the wheel, rotate it 901, tighten the wheel, and recheck the balance. Repeat this three more times, until the wheel returns to its original position. The balancer should not indicate any more than 5 grams of additional weight is needed during this procedure. If more than 5 grams is indicated, calibrate or repair the balancer. 3. Remove the weights just installed. Make sure the balancer is set to its finest balancing mode (accuracy within 5 grams). 4. Perform a dynamic balance, adding weights as indicated by the balancer to both sides of the wheel. 5. Once the wheel is in dynamic balance, add an additional 5 grams at any point on the rim and recheck the balance. The balancer should indicate that 5 grams is needed on the same side of the wheel at a point exactly opposite the weight you added. If so, the balancer is in calibration. If the balancer indicates that more than 10 grams is needed, or the indicated position is more than 1.5 inches from the point exactly opposite the weight you added, then the balancer needs calibration or repair. PARTS INFORMATION WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. Failed part: P/N 42700-SM1-A01 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 94025 > Aug > 94 > Steering - Wheel Oscillates or Has a Shimmy > Page 7233 H/C 3251550 Defect code: 045 Contention code: B99 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 06-082 > Dec > 06 > Tires - Tubless Tire Repair Information Tires: All Technical Service Bulletins Tires - Tubless Tire Repair Information 06-082 December 15, 2006 Applies To: ALL Tubeless Tire Repair Information This service bulletin provides the resource information required to repair tubeless tires on Honda automobiles and light trucks. To properly repair a tire, follow the Rubber Manufacturers Association (RMA) "Puncture Repair Procedures for Passenger and Light Truck Tires" outlined on the RMA wall poster. One wall poster has been provided to your dealership. Additional posters can be ordered through Helm, the RMA website, www.rma.org, or the tire manufacturers. Michelin(R) PAX System(TM), tires can be repaired using the same repair procedures described on the RMA poster. Whenever you repair a PAX System tire, you must inspect the support ring. Refer to the PAX System support ring section of this service bulletin for inspection procedures. WARRANTY CLAIM INFORMATION Refer to the tire manufacturer for warranty information. REQUIRED MATERIALS ^ 1/8 inch Patch-plug with lead wire ^ 1/4 inch Patch-plug with lead wire ^ 1/8 inch Plugs (stem)* ^ 1/4 inch Plugs (stem)* ^ 1/4 inch Patches* ^ 3/4 inch Patches* ^ Chemical cement ^ Liquid buffer ^ Rim-bead sealer ^ Inner liner sealer REQUIRED TOOLS ^ Tire stitcher, 1-1/2 inch wheel ^ Tire crayons ^ Tire test tank ^ Awl or probe ^ Flexible blade skiving knife ^ 1/8 inch Carbide tire tool with adapter ^ 1/4 inch Carbide tire tool with adapter ^ Low speed buffer with quick release chuck and exhaust hose ^ Carbide buffing wheel with adapter Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 06-082 > Dec > 06 > Tires - Tubless Tire Repair Information > Page 7239 ^ Reversible drill motor (800 RPM MAX) ^ Tire spreader ^ Inspection lamp * For repairable injuries that exceed 25 degrees TIRE REPAIR GUIDELINES Never repair tires worn below 2/32 inch of tread. Never repair a tire without removing the tire from the wheel for internal inspection. Never repair a tire with a tread injury larger than 1/4 inch (6 mm). Never use only a plug (stem) or a patch only to repair a tire injury. NOTE: If the angle of the tire injury exceeds 25 degrees, you must use the two-piece repair system as recommended by the RMA. MICHELIN PAX SYSTEM SUPPORT RING INSPECTION PAX System support rings are not repairable, under any circumstances, but they can be reused if no damage is found during a thorough inspection. If a PAX System tire ran flat or underinflated, dismount the tire from the wheel and inspect the wheel, tire, and support ring for damage. Refer to the Michelin PAX Support Rings Technical Bulletin in ISIS. Enter SEARCH BY PUBLICATION, select Job Aids, then select Michelin PAX Support Rings Technical Bulletin from the list. Disclaimer Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 94025 > Aug > 94 > Steering - Wheel Oscillates or Has a Shimmy Tires: All Technical Service Bulletins Steering - Wheel Oscillates or Has a Shimmy Bulletin No. 94-025 Model ALL Applicable To ALL File Under SUSPENSION Issue Date AUG 22, 1994 Steering Wheel Shimmy SYMPTOM The steering wheel oscillates, or shimmies, when driving between 58 and 62 mph. It may be most noticeable on smooth roads, and may vary with slight steering inputs. PROBABLE CAUSE An imbalance of the wheel/tire/hub/disc assembly in the front end. CORRECTIVE ACTION Dynamically balance the wheel and tire assembly off the car. Then, if necessary, use the Hofmann Finish Wheel Balancer to balance the wheel/tire/hub/disc assembly on the car. 1. Drive the car on a smooth surface between 58 and 62 mph. Turn the steering wheel slightly, and allow the steering to self-center. Repeat this several times and observe the steering wheel motion. If the steering wheel does not oscillate, or the movement is different than shown below, the car does not have an imbalance problem. Do not continue with this procedure. If the steering wheel oscillates as shown, continue with this procedure. 2. Dynamically balance all four wheel/tire assemblies off the car. Make sure the balancer is capable of balancing to an accuracy of within 5 grams. Use only Honda wheel weights (see PARTS INFORMATION). NOTE: To verify the balancer's accuracy and calibration, refer to the DYNAMIC OFF-CAR WHEEL BALANCER CALIBRATION CHECK. 3. Reinstall the balanced wheel/tire assemblies and torque the wheel nuts to 80 lb.ft. Do not use an impact wrench to snug up or torque the wheel nuts; it may damage or distort the wheel and cause steering wheel oscillation. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 94025 > Aug > 94 > Steering - Wheel Oscillates or Has a Shimmy > Page 7244 4. Road test the car and check for steering wheel oscillation. If it still oscillates, use the Hofmann Finish Wheel Balancer to do a finish balance on the front wheel/tire/hub/disc assemblies. NOTE: Refer to section 4 of the Hofmann DAFB-10 Finish Wheel Balancer Operator's Manual that came with the unit for detailed instructions. DYNAMIC OFF-CAR WHEEL BALANCER CALIBRATION CHECK Use this procedure to determine if the balancer is accurate to within 5 grams of imbalance. If the balancer is not accurate to within 5 grams, it must be calibrated or repaired before being used to correct a steering wheel oscillation problem. You will need a Honda factory or accessory alloy wheel only, with no tire mounted, to perform this procedure. 1. Before starting, make sure the wheel has no balance weights. Perform a static balance, adding weights as necessary to only one side of the wheel. 2. Loosen the wheel, rotate it 901, tighten the wheel, and recheck the balance. Repeat this three more times, until the wheel returns to its original position. The balancer should not indicate any more than 5 grams of additional weight is needed during this procedure. If more than 5 grams is indicated, calibrate or repair the balancer. 3. Remove the weights just installed. Make sure the balancer is set to its finest balancing mode (accuracy within 5 grams). 4. Perform a dynamic balance, adding weights as indicated by the balancer to both sides of the wheel. 5. Once the wheel is in dynamic balance, add an additional 5 grams at any point on the rim and recheck the balance. The balancer should indicate that 5 grams is needed on the same side of the wheel at a point exactly opposite the weight you added. If so, the balancer is in calibration. If the balancer indicates that more than 10 grams is needed, or the indicated position is more than 1.5 inches from the point exactly opposite the weight you added, then the balancer needs calibration or repair. PARTS INFORMATION WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. Failed part: P/N 42700-SM1-A01 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 94025 > Aug > 94 > Steering - Wheel Oscillates or Has a Shimmy > Page 7245 H/C 3251550 Defect code: 045 Contention code: B99 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 06-082 > Dec > 06 > Tires - Tubless Tire Repair Information Tires: All Technical Service Bulletins Tires - Tubless Tire Repair Information 06-082 December 15, 2006 Applies To: ALL Tubeless Tire Repair Information This service bulletin provides the resource information required to repair tubeless tires on Honda automobiles and light trucks. To properly repair a tire, follow the Rubber Manufacturers Association (RMA) "Puncture Repair Procedures for Passenger and Light Truck Tires" outlined on the RMA wall poster. One wall poster has been provided to your dealership. Additional posters can be ordered through Helm, the RMA website, www.rma.org, or the tire manufacturers. Michelin(R) PAX System(TM), tires can be repaired using the same repair procedures described on the RMA poster. Whenever you repair a PAX System tire, you must inspect the support ring. Refer to the PAX System support ring section of this service bulletin for inspection procedures. WARRANTY CLAIM INFORMATION Refer to the tire manufacturer for warranty information. REQUIRED MATERIALS ^ 1/8 inch Patch-plug with lead wire ^ 1/4 inch Patch-plug with lead wire ^ 1/8 inch Plugs (stem)* ^ 1/4 inch Plugs (stem)* ^ 1/4 inch Patches* ^ 3/4 inch Patches* ^ Chemical cement ^ Liquid buffer ^ Rim-bead sealer ^ Inner liner sealer REQUIRED TOOLS ^ Tire stitcher, 1-1/2 inch wheel ^ Tire crayons ^ Tire test tank ^ Awl or probe ^ Flexible blade skiving knife ^ 1/8 inch Carbide tire tool with adapter ^ 1/4 inch Carbide tire tool with adapter ^ Low speed buffer with quick release chuck and exhaust hose ^ Carbide buffing wheel with adapter Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 06-082 > Dec > 06 > Tires - Tubless Tire Repair Information > Page 7251 ^ Reversible drill motor (800 RPM MAX) ^ Tire spreader ^ Inspection lamp * For repairable injuries that exceed 25 degrees TIRE REPAIR GUIDELINES Never repair tires worn below 2/32 inch of tread. Never repair a tire without removing the tire from the wheel for internal inspection. Never repair a tire with a tread injury larger than 1/4 inch (6 mm). Never use only a plug (stem) or a patch only to repair a tire injury. NOTE: If the angle of the tire injury exceeds 25 degrees, you must use the two-piece repair system as recommended by the RMA. MICHELIN PAX SYSTEM SUPPORT RING INSPECTION PAX System support rings are not repairable, under any circumstances, but they can be reused if no damage is found during a thorough inspection. If a PAX System tire ran flat or underinflated, dismount the tire from the wheel and inspect the wheel, tire, and support ring for damage. Refer to the Michelin PAX Support Rings Technical Bulletin in ISIS. Enter SEARCH BY PUBLICATION, select Job Aids, then select Michelin PAX Support Rings Technical Bulletin from the list. Disclaimer Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service Precautions > Technician Safety Information Tires: Technician Safety Information WARNING: This vehicle has a Supplemental Restraint System (SRS). Refer to the SRS component and wiring location view in order to determine whether you are performing service on or near the SRS components or the SRS wiring. when you are performing service on or near the SRS components or the SRS wiring, refer to the SRS service information. failure to follow warnings could result in possible air bag deployment, personal injury, or otherwise unneeded SRS system repairs. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service Precautions > Technician Safety Information > Page 7254 Tires: Vehicle Damage Warnings CAUTION: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. Honda will call out those fasteners that require a replacement after removal. Honda will also call out the fasteners that require thread lockers or thread sealant. Unless otherwise specified, do not use supplemental coatings (Paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and the joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service Precautions > Page 7255 Tires: Description and Operation GENERAL DESCRIPTION Replacement wheels or tires must be equivalent to the originals in load capacity, specified dimension and mounting configuration. Improper size or type may affect bearing life, brake performance, speedometer/odometer calibration, vehicle ground clearance and tire clearance to the body and chassis. All model are equipped with metric sized tubeless steel belted radial tires. Correct tire pressures and driving habits have an important influence on tire life. Heavy cornering, excessively rapid acceleration and unnecessary sharp braking increase premature and uneven wear. TREAD WEAR INDICATORS The original equipment tires have built-in tread wear indicators (1) to show when tires need replacement. These indicators may appear as wide bands. When the indicators appear in two or more grooves at three locations, tire replacement is recommended. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Testing and Inspection > Abnormal Tire Ahead Wear and Major Causes Tires: Testing and Inspection Abnormal Tire Ahead Wear and Major Causes TYPICAL EXAMPLES OF ABNORMAL TIRE AHEAD WEAR AND MAJOR CAUSES: CAUTION: Similar wear patterns can be caused by worn suspension parts, misalignment of wheels and tires, and other suspension related problems. Spotty Wear Wear localized on shoulder sections, and in an extreme cases, the tire becomes polygonal in shape. 1. Tire or wheel out of round or distorted. 2. Hub or knuckle out of round or distorted. 3. Play in hub bearings or ball joint. 4. Rotating parts out of balance. Tread Wear One-Sided 1. Rotating parts out of balance. 2. Tire or wheel out of round. 3. Hub or knuckle out of round or distorted. Localized Tread Wear Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Testing and Inspection > Abnormal Tire Ahead Wear and Major Causes > Page 7258 1. Once spotty wear develops in tread due to hard braking or abrupt starting, localized wear tends to be promoted. Shoulder Wear (Generally Wear Develops In Outer Shoulder): 1. Camber or toe-in incorrect. 2. Shoulder wear caused by repeated hard-cornering. Wear In Shoulders At Points Opposed To Each Other 1. Tire or wheel out of round or distorted. 2. Play in bearings or ball joint. Premature Wear In Shoulders 1. Flexing of tire excessive due to under-inflation. One Sided Feather Edging 1. Wear caused by repeated hard cornering. 2. Camber or toe-in incorrect. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Testing and Inspection > Abnormal Tire Ahead Wear and Major Causes > Page 7259 Tires: Testing and Inspection Diagnosis By Symptom Part 1 Of 2 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Testing and Inspection > Abnormal Tire Ahead Wear and Major Causes > Page 7260 Part 2 Of 2 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Testing and Inspection > Abnormal Tire Ahead Wear and Major Causes > Page 7261 Tires: Testing and Inspection Diagnosis List If the following conditions are noted, rotation is required. 1. Front tire wear is different from rear. 2. Uneven wear exists across the tread of any tire. 3. Left and right front tire wear is unequal. 4. Left and right rear tire wear is unequal. If the following conditions are noted, check the wheel alignment. 1. Left and right front tire wear is unequal. 2. Uneven wear exists across the tread of any tire. 3. Front tire treads have scuffed appearance with "feather" edges on one side of tread ribs or blocks. 4. There is cupping, flat spotting etc. Higher than recommended pressure can cause: 1. Hard ride. 2. Poor steering stability. 3. Rapid and uneven wear at center of the tread. Lower than recommended pressure can cause: 1. Tire squeal on turns. 2. Hard steering. 3. Rapid and uneven wear on the edges of the tread. 4. Tire rim bruises and rupture. 5. Tire cord breakage. 6. High tire temperatures. 7. Reduced handling. 8. Reduced fuel economy. Unequal pressure on same axle can cause: 1. Uneven braking. 2. Steering lead. 3. Reduced handling. 4. Swerve on acceleration. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Testing and Inspection > Abnormal Tire Ahead Wear and Major Causes > Page 7262 Tires: Testing and Inspection Irregular and Premature Wear Irregular and/or premature wear has many causes. Some of them are incorrect inflation pressures, lack of tire rotation, poor driving habits or improper wheel alignment. Incorrect inflation is common cause of tire premature wear. NOTE: Due to their design, radial tires tend to wear faster in the shoulder area, particularly on the front tires. This makes regular rotation especially necessary. After rotation, be sure to check wheel nut torque, and set tire pressures. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Testing and Inspection > Abnormal Tire Ahead Wear and Major Causes > Page 7263 Tires: Testing and Inspection Abnormal Tire Ahead Wear and Major Causes TYPICAL EXAMPLES OF ABNORMAL TIRE AHEAD WEAR AND MAJOR CAUSES: CAUTION: Similar wear patterns can be caused by worn suspension parts, misalignment of wheels and tires, and other suspension related problems. Spotty Wear Wear localized on shoulder sections, and in an extreme cases, the tire becomes polygonal in shape. 1. Tire or wheel out of round or distorted. 2. Hub or knuckle out of round or distorted. 3. Play in hub bearings or ball joint. 4. Rotating parts out of balance. Tread Wear One-Sided 1. Rotating parts out of balance. 2. Tire or wheel out of round. 3. Hub or knuckle out of round or distorted. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Testing and Inspection > Abnormal Tire Ahead Wear and Major Causes > Page 7264 Localized Tread Wear 1. Once spotty wear develops in tread due to hard braking or abrupt starting, localized wear tends to be promoted. Shoulder Wear (Generally Wear Develops In Outer Shoulder): 1. Camber or toe-in incorrect. 2. Shoulder wear caused by repeated hard-cornering. Wear In Shoulders At Points Opposed To Each Other 1. Tire or wheel out of round or distorted. 2. Play in bearings or ball joint. Premature Wear In Shoulders 1. Flexing of tire excessive due to under-inflation. One Sided Feather Edging 1. Wear caused by repeated hard cornering. 2. Camber or toe-in incorrect. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Testing and Inspection > Abnormal Tire Ahead Wear and Major Causes > Page 7265 Part 1 Of 2 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Testing and Inspection > Abnormal Tire Ahead Wear and Major Causes > Page 7266 Part 2 Of 2 Diagnosis List If the following conditions are noted, rotation is required. 1. Front tire wear is different from rear. 2. Uneven wear exists across the tread of any tire. 3. Left and right front tire wear is unequal. 4. Left and right rear tire wear is unequal. If the following conditions are noted, check the wheel alignment. 1. Left and right front tire wear is unequal. 2. Uneven wear exists across the tread of any tire. 3. Front tire treads have scuffed appearance with "feather" edges on one side of tread ribs or blocks. 4. There is cupping, flat spotting etc. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Testing and Inspection > Abnormal Tire Ahead Wear and Major Causes > Page 7267 Higher than recommended pressure can cause: 1. Hard ride. 2. Poor steering stability. 3. Rapid and uneven wear at center of the tread. Lower than recommended pressure can cause: 1. Tire squeal on turns. 2. Hard steering. 3. Rapid and uneven wear on the edges of the tread. 4. Tire rim bruises and rupture. 5. Tire cord breakage. 6. High tire temperatures. 7. Reduced handling. 8. Reduced fuel economy. Unequal pressure on same axle can cause: 1. Uneven braking. 2. Steering lead. 3. Reduced handling. 4. Swerve on acceleration. Irregular and Premature Wear Irregular and/or premature wear has many causes. Some of them are incorrect inflation pressures, lack of tire rotation, poor driving habits or improper wheel alignment. Incorrect inflation is common cause of tire premature wear. NOTE: Due to their design, radial tires tend to wear faster in the shoulder area, particularly on the front tires. This makes regular rotation especially necessary. After rotation, be sure to check wheel nut torque, and set tire pressures. Radial Tire Lead/Pull "Lead/Pull" is vehicle deviation from a straight path, on a level road with no pressure on the steering wheel. Lead is usually caused by: 1. Poorly manufactured radial tires. 2. Uneven brake adjustment. 3. Wheel alignment. The way in which a tire is built can produce lead in a car. An example of this is placement of the belt. Off-center belts on radial tires can cause the tire to develop a side force while rolling straight down the road and the tire will tend to roll like a cone. The "Radial Tire Lead/Pull Correction" chart should be used to make sure that front wheel alignment is not mistaken for tire lead. Rear tires will not cause lead/pull. Radial Tire Waddle Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Testing and Inspection > Abnormal Tire Ahead Wear and Major Causes > Page 7268 Waddle is side-to-side movement at the front and/or rear of the car. It can be caused by the steel belt not being straight within the tire, or by excessive lateral runout of the tire or wheel. It is most noticeable at low speed, about 8 to 48 km/h (5 to 30 mph). It may also cause rough ride at 80 to 113 km/h (50 to 70 mph). The car can be road tested to see which end of the car has the faulty tire. If the tire causing the waddle is on the rear, the rear end of the car will "waddle". From the driver's seat, it feels as if someone is pushing on the side of the car. If the faulty tire is on the front, the waddle is more easily seen. The front sheet metal appears to be moving back and forth. It feels as if the driver's seat is the pivot point in the car. Another more time-consuming method of determining the faulty tire is substituting tire and wheel assemblies that are known to be good. Follow these steps: 1. Drive the car to determine if the waddle is coming from the front or rear. 2. Install tire and wheel assemblies known to be good (from a similar car) in place of those on the end of the car which is waddling. If the waddle cannot be isolated to front or rear, start with the rear tires. 3. Road test again. If improvement is noted, install the original tire and wheel assemblies one at a time until the faulty tire is found. If no improvement is noted, install tires known to be good in place of all four. Then, install the originals one at a time until the faulty tire is found. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service and Repair > Separating the Tire From the Wheel Tires: Service and Repair Separating the Tire From the Wheel Use a tire changing machine to demount tires. Do not use hand tools or tire irons alone to remove the tire from the wheel. Damage to the tire beads or wheel rim could result. Follow the tire changing machine manufacturer's instructions to properly separate the tire from the wheel. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service and Repair > Separating the Tire From the Wheel > Page 7271 Tires: Service and Repair Mounting the Tire on the Wheel CAUTION: Recommended vehicle tire mounting and inflation procedures are especially important with radial tires. Failure to follow these procedures can cause bead deformation in both tube type and tubeless tires due to incorrect bead seating. Bead deformation may lead to chafing, lower sidewall and bead area cracking, eccentric wear, ride vibration and nonretreadable casings. Only use rims approved for radial tire usage by the rim manufacture. 1. Clean the rim. Remove all rust and other foreign material. 2. Lubricate tire beads and rim bead seats with an approved rubber lubricant. CAUTION: Do not use silicon base lubricants. This could cause the tire to slip on the wheel. 3. Attach the tire to the wheel. a. Use a tire changing machine. b. Align air valve and tire balancing match marks (about 8 mm diameter paint mark). Hold in this position and inflate the until the tire beads are firmly seated on the rim against the flanges (steel wheel model only). 4. Inflate the tire to operating pressure. 5. Check the bead seating. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service and Repair > Separating the Tire From the Wheel > Page 7272 Tires: Service and Repair Balancing Deposits of mud, etc. must be cleaned from the inside of the rim. The tire should be inspected for the following: match mount paint marks, bent rims, bulges, irregular tire wear, proper wheel size and inflation pressure. Then balance according to the equipment manufacturer's recommendations. There are two types of wheel and tire balance: a. Static balance is the equal distribution of weight around the wheel. Assemblies that are statically unbalanced cause a bouncing action called tramp. This condition will eventually cause uneven tire wear. b. Dynamic balance is the equal distribution of weight on each side of the wheel center-line so that when the tire spins there is no tendency for the assembly to move from side to side. Assemblies that are dynamically unbalanced may cause shimmy. WARNING: Stones should be removed from the tread to avoid operator injury during spin balancing and to obtain a good balance. NOTE: Using wheel balancing equipment. Follow the tire balancing machine manufacturer's instructions to properly balance wheel and tire. Balance weight for the wheel should not exceed 170 g in total, and 140 g is the maximum amount for either side. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service and Repair > Separating the Tire From the Wheel > Page 7273 Tires: Service and Repair Tire Rotation Tire rotation is recommended to equalize wear for longer life. If the following conditions are noted, rotate the tires: - Front tire wear is different from rear. - Uneven wear exists across the tread of any tire. - Left and right front tire wear is unequal. - Left and right rear tire wear is unequal. Check wheel alignment if the following conditions are noted: - Left and right front tire wear is unequal. - Wear is uneven across the tread of any front tire. - Front tire treads have a scuffed appearance with "feather" edges on one side of the tread ribs or blocks. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service and Repair > Separating the Tire From the Wheel > Page 7274 Tires: Service and Repair Separating the Tire From the Wheel Use a tire changing machine to demount tires. Do not use hand tools or tire irons alone to remove the tire from the wheel. Damage to the tire beads or wheel rim could result. Follow the tire changing machine manufacturer's instructions to properly separate the tire from the wheel. Mounting the Tire on the Wheel CAUTION: Recommended vehicle tire mounting and inflation procedures are especially important with radial tires. Failure to follow these procedures can cause bead deformation in both tube type and tubeless tires due to incorrect bead seating. Bead deformation may lead to chafing, lower sidewall and bead area cracking, eccentric wear, ride vibration and nonretreadable casings. Only use rims approved for radial tire usage by the rim manufacture. 1. Clean the rim. Remove all rust and other foreign material. 2. Lubricate tire beads and rim bead seats with an approved rubber lubricant. CAUTION: Do not use silicon base lubricants. This could cause the tire to slip on the wheel. 3. Attach the tire to the wheel. a. Use a tire changing machine. b. Align air valve and tire balancing match marks (about 8 mm diameter paint mark). Hold in this position and inflate the until the tire beads are firmly seated on the rim against the flanges (steel wheel model only). 4. Inflate the tire to operating pressure. 5. Check the bead seating. Balancing Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service and Repair > Separating the Tire From the Wheel > Page 7275 Deposits of mud, etc. must be cleaned from the inside of the rim. The tire should be inspected for the following: match mount paint marks, bent rims, bulges, irregular tire wear, proper wheel size and inflation pressure. Then balance according to the equipment manufacturer's recommendations. There are two types of wheel and tire balance: a. Static balance is the equal distribution of weight around the wheel. Assemblies that are statically unbalanced cause a bouncing action called tramp. This condition will eventually cause uneven tire wear. b. Dynamic balance is the equal distribution of weight on each side of the wheel center-line so that when the tire spins there is no tendency for the assembly to move from side to side. Assemblies that are dynamically unbalanced may cause shimmy. WARNING: Stones should be removed from the tread to avoid operator injury during spin balancing and to obtain a good balance. NOTE: Using wheel balancing equipment. Follow the tire balancing machine manufacturer's instructions to properly balance wheel and tire. Balance weight for the wheel should not exceed 170 g in total, and 140 g is the maximum amount for either side. Tire Rotation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service and Repair > Separating the Tire From the Wheel > Page 7276 Tire rotation is recommended to equalize wear for longer life. If the following conditions are noted, rotate the tires: - Front tire wear is different from rear. - Uneven wear exists across the tread of any tire. - Left and right front tire wear is unequal. - Left and right rear tire wear is unequal. Check wheel alignment if the following conditions are noted: - Left and right front tire wear is unequal. - Wear is uneven across the tread of any front tire. - Front tire treads have a scuffed appearance with "feather" edges on one side of the tread ribs or blocks. Inflation of Tires Tire pressure, in cold condition (after vehicle has set for three hours or more, and driven less than one mile) should be checked monthly or before any extended trip. Tire pressure increases approximately 15% when the tires become hot during driving. Tire pressure specification is shown on the label located on the left door lock pillar. NOTE: Check the tire pressure whenever irregular wear is found. Tire inflation greatly affects tire wear. If the alignment check does not reveal any alignment problems, check the condition of the shock absorbers and wheel/tire balance. Tire Replacement TIRE REPLACEMENT When replacement is necessary, the original metric the size should be used. Most metric tire sizes do not have exact corresponding alphanumeric tire sizes. It is recommended that new tires be installed in pairs on the same axle. If necessary to replace only one tire, it should be paired with tire having the most tread, to equalize braking traction. CAUTION: Do not mix different types of tires such as radial, bias and bias-belted tires except in emergencies, because vehicle handling may be seriously affected and may result in loss of control. Tire Dismounting Remove valve cap on valve step and deflate the tire. Then use a tire changing machine to mount or dismount tires. Follow the equipment manufacturer's instruction. Do not use hand tools or tire lever alone to change tires as they may damage the tire beads or wheel rim. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service and Repair > Separating the Tire From the Wheel > Page 7277 Tire Mounting Rim bead seats should be cleaned with a wire brush or coarse steel wool to remove lubricants, and light rust. Before mounting a tire, the bead area should be well lubricated with an approved tire lubricant. After mounting, inflate the tire to 196 kPa (28 psi) so that beads are completely seated. Inflate the air to specified pressure and install valve cap to the stem. WARNING: Never stand over tire when inflating. bead may break when bead snaps over rim's safety hump and cause serious personal injury. never exceed 240 kPa (35 psi) pressure when inflating. if 240 kPa (35 psi) pressure will not seat beads, deflate, re-lubricate and re-inflate. over inflation may cause the bead to break and cause serious personal injury. Tire Repair There are many different materials on the market used to repair tires. Manufacturers have published detailed instructions on how and when to repair tires. These instructions can be obtained from the tire manufacturer if they are not included with the repair kit. Wheel Inspection Damaged wheels and wheels with excessive run-out must be replaced. Wheel run out at rim (Base on hub Bore): General Balance Procedure Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service and Repair > Separating the Tire From the Wheel > Page 7278 Deposits of mud, etc. must be cleaned from the inside of the rim. The tire should be inspected for the following: match mount paint marks, bent rims, bulges, irregular tire wear, proper wheel size and inflation pressure. Then balance according to the equipment manufacturer's recommendations. There are two types of wheel and tire balance. Static balance is the equal distribution of weight around the wheel. Assemblies that are statically unbalanced cause a bouncing action called tramp. This condition will eventually cause uneven tire wear. Dynamic balance is the equal distribution of weight on each side of the wheel center-line so that when the tire spins there is no tendency for the assembly to move from side to side. Assemblies that are dynamically unbalanced may cause shimmy. WARNING: Stones should be removed from the tread to avoid operator injury during spin balancing and to obtain a good balance. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Adjustments Wheel Bearing: Adjustments Wheel bearings and hub on these models are an integral assembly and bearings cannot be adjusted. If hub endplay exceeds 0.002 inch with spindle nut properly tightened, hub and bearing assembly should be replaced. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension Wheel Bearing: Service and Repair Front Suspension 1. Raise and support front of vehicle, then remove front wheels. 2. Raise spindle nut locking tab, then remove spindle nut. 3. Remove brake hose bracket mounting bolts. 4. Remove caliper and position aside. Do not allow caliper assembly to hang from brake hose. 5. Remove brake disc attaching screws, then thread two 8 x 1.25 x 12 mm bolts into attaching screw holes to push disc from hub. When tightening screws, turn only two turns at a time to prevent excessively cocking the brake disc. 6. Remove brake disc from knuckle. 7. Remove speed sensor wire bracket, then the speed sensor from knuckle. 8. Remove tie rod end cotter pin and nut. 9. Remove tie rod end using suitable tie rod end remover. 10. Remove lower ball joint cotter pin, then loosen ball joint nut half way. 11. Using ball joint remover tool No. 07MAC-SL00200, or equivalent, separate ball joint and lower arm. 12. Remove upper ball joint shield, then the cotter pin and nut. 13. Separate upper ball joint from upper arm using suitable ball joint remover. 14. Remove steering knuckle and hub assembly by sliding off driveshaft. 15. Remove hub from steering knuckle using suitable press. 16. Remove knuckle ring, circlip and splash guard from knuckle. 17. Press out wheel bearing from hub using driver tool No. 07749-0010000, attachment tool No. 07746-0010500 and base tool No. 07GAF-SE00401, or equivalents. 18. Remove outboard bearing inner race from hub. Fig. 4 Front Suspension 19. Reverse procedure to install. Refer to Fig. 2 for tightening specifications. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 7284 Wheel Bearing: Service and Repair Rear Suspension Disc Brake Models 1. Raise and support vehicle, then remove rear wheels. 2. Apply parking brake, then remove hub cap. 3. Raise locking tab on spindle nut, then remove nut. 4. Remove 6 mm brake disc retaining screw, then the caliper shield. 5. Remove brake hose mounting bolts, then the caliper bracket mounting bolts. 6. Remove caliper and hang from undercarriage with short piece of wire. Do not hang caliper by brake hose. 7. Screw two 12 mm bolts into disc to push disc off of hub. Remove disc. 8. Remove hub unit from knuckle. 9. Reverse procedure to install. Drum Brake Models 1. Raise and support rear of vehicle, then remove wheel and brake drum. 2. Remove grease cap, spindle nut and washer. 3. Remove hub and bearing unit from spindle. 4. Reverse procedure to install. Tighten spindle nut to specifications, then stake shoulder of nut into groove in spindle. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Component .......................................................................................................................................... .......................................................... Torque/Ft. Lbs. Spindle Nut ...................................................... .............................................................................................................................................................. .. 134 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications TIGHTENING SPECIFICATIONS Wheel Nut ............................................................................................................................................ ................................................... 110 Nm (80 ft. lbs.) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Air Conditioning Switch > Component Information > Testing and Inspection Air Conditioning Switch: Testing and Inspection A/C Switch Test Check for continuity between the terminals according to the table below. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Component Information > Diagrams > Diagram Information and Instructions Air Door: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7300 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7301 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7302 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7303 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7304 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7305 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7306 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7307 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7308 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7309 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7310 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7311 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7312 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7313 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7314 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7315 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7316 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7317 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7318 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7319 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7320 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7321 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7322 Air Door: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7323 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7324 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7325 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7326 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7327 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7328 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7329 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7330 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7331 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7332 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7333 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7334 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7335 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7336 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7337 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7338 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7339 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7340 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7341 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7342 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7343 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7344 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7345 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7346 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7347 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7348 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Blower (Heater) Motor Gets Hot and Blows A Fuse Blower Motor: Technical Service Bulletins Blower (Heater) Motor Gets Hot and Blows A Fuse SOURCE: Honda Service News November 2003 TITLE: Heater Blower Motor Gets Hot or Blows a Fuse APPLIES TO: 1990-04 Accords, 1992-04 Civics, 1997-04 CR-Vs, 2003 Elements, 2000-04 Insights, 1995-04 Odysseys, 1996-02 Passports, 2003-04 Pilots, 1997-01 Preludes, and 2000-04 S2000s SERVICE TIP: A blocked cooling hose for the heater blower motor can cause the motor to overheat, draw more current, blow a fuse, or even melt its plastic impeller. Before you order a replacement blower motor, make sure the cooling hose isn't blocked. On some models, you'll find the cooling hose molded into the blower motor housing; on other models, it's a separate piece. Check the S/M for the vehicle you're working on to determine the actual location of the cooling hose. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Page 7353 Blower Motor: Locations Below Right Side Of Dash Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions Blower Motor: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7356 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7357 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7358 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7359 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7360 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7361 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7362 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7363 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7364 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7365 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7366 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7367 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7368 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7369 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7370 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7371 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7372 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7373 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7374 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7375 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7376 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7377 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7378 Blower Motor: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7379 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7380 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7381 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7382 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7383 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7384 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7385 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7386 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7387 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7388 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7389 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7390 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7391 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7392 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7393 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7394 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7395 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7396 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7397 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7398 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7399 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7400 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7401 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7402 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7403 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7404 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Blower Unit Blower Motor: Service and Repair Blower Unit SRS Main Harness CAUTION: All SRS electrical wiring harnesses are covered with yellow outer insulation. Before disconnecting the SRS wire harness, install the short connector (5) on the airbag (5). Replace the entire affected SRS harness assembly it it has an open circuit or damaged wiring. 1. Disconnect the battery negative terminal. 2. Remove the glove box and glove box frame. 3. Remove the tapping screws (2) and remove the heater duct. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Blower Unit > Page 7407 4. Remove the A/C band and the evaporator. 5. Remove the mounting bolts (3). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Blower Unit > Page 7408 6. Disconnect the connectors from the blower motor. resistor then remove the blower. 7. Install the blower in the reverse order of removal and make sure there is no air leakage. NOTE: Before assembly make cure that the air door and linkage moves smoothly without binding. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Blower Unit > Page 7409 Blower Motor: Service and Repair Blower Motor NOTE: The blower motor, recirculation control motor, end resistor can be replaced without removing the blower assembly SRS Main Harness CAUTION: All SRS electrical wiring harnesses are covered with yellow outer insulation. Before disconnecting the SRS wire harness, install the short connector (5) on the airbag (5). Replace the entire affected SRS harness assembly it it has an open circuit or damaged wiring. 1. Disconnect the battery negative terminal. 2. Remove the glove box and glove box frame. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Blower Unit > Page 7410 6. Disconnect the connectors from the blower motor. resistor then remove the blower. 7. Install the blower in the reverse order of removal and make sure there is no air leakage. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations Blower Motor Relay: Locations Right Rear Corner Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Page 7414 Blower Motor Relay: Testing and Inspection Relay Test - There should be continuity between the C and D terminals. - There should be continuity between the A and B terminals when power and ground are connected to the C and D terminals. - There should be no continuity when power is disconnected. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations Blower Motor Resistor: Locations Behind Glove Box Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions Blower Motor Switch: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7422 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7423 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7424 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7425 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7426 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7427 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7428 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7429 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7430 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7431 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7432 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7433 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7434 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7435 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7436 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7437 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7438 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7439 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7440 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7441 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7442 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7443 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7444 Blower Motor Switch: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7445 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7446 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7447 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7448 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7449 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7450 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7451 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7452 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7453 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7454 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7455 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7456 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7457 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7458 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7459 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7460 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7461 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7462 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7463 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7464 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7465 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7466 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7467 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7468 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7469 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7470 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Page 7471 Blower Motor Switch: Testing and Inspection Heater Fan Switch Test Check for continuity between the terminals according to the table below. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Electrical Specifications Compressor Clutch: Electrical Specifications SANDEN Field Coil Resistance 3.05 - 3.35 ohms at 68 Deg F NIPPONDENSO Stator Coil Resistance 3.4 - 3.8 ohms at 68 Deg F Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Electrical Specifications > Page 7477 Compressor Clutch: Mechanical Specifications SANDEN Pulley-to-pressure plate clearance 0.5+/-0.15 mm NIPPONDENSO Pulley-to-pressure plate clearance 0.5+/-0.15 mm Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 7478 Compressor Clutch: Locations Photo 3 - A/C Compressor Thermal Protector Left Front Corner Of Engine Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 7479 Compressor Clutch: Testing and Inspection Clutch Inspection - Check the rotor pulley bearing play and drag by rotating the rotor pulley by hand. Replace the clutch set with a new one if it is noisy or has excessive play/drag. - Turn the rotor pulley by hand and measure the clearance between the rotor pulley and armature plate all the way around. If the clearance is not within specified limits, the armature plate must be removed and shims added or removed as required. CLEARANCE: 0.50 ± 0.15 mm (0.020 ± 0.006 in) NOTE: The shims are available in four sizes: 0.1 mm, 0.2 mm, 0.4 mm and 0.5 mm of thickness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 7480 - Release the compressor clutch connector from the connector holder. Check the thermal protector for continuity. If there is no continuity, replace the thermal protector. - Check the field coil for resistance. Field Coil Resistance: 3.2 ± 0.15 ohm at 68°F (20°C) If resistance is not within specifications, replace the field coil. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 7481 Compressor Clutch: Service and Repair Clutch Overhaul 1. Remove the center nut while holding the armature plate. 2. Remove the armature plate by pulling it up by hand. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 7482 3. Remove the snap ring B with a snap ring pliers. NOTE: ^ Once the snap ring B was removed, replace it with a new one. ^ Be careful not to damage the compressor body and rotor pulley during removal/installation. 4. Remove the rotor pulley from the shaft with a puller and the special tool. NOTE: Put the claws of the puller on the back of the rotor pulley, not on the belt area; otherwise the rotor pulley can be damaged. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 7483 5. Remove the snap ring A with a snap ring pliers. Release the field coil connector from the connector holder, and disconnect the connector and field coil ground terminal. Remove the field coil from the compressor. NOTE: ^ Once the snap ring A is removed, replace it with a new one. ^ When installing the field coil, align the boss on the field coil with the hole in the compressor. 6. Position the rotor pulley squarely over field coil. Press the rotor pulley onto the compressor boss with the special tool. If the rotor pulley does not press on straight, remove ~ and check the rotor pulley and compressor boss for burrs or damage. 7. Install in the reverse order of removal, and: ^ Clean the rotor pulley and compressor sliding surfaces with non-petroleum solvent. ^ Install the snap rings with the chamfered side facing out and make sure the snap rings are in the groove completely. ^ After installing, make sure that the rotor pulley turns smoothly. ^ Route and clamp the wires properly or they can be damaged by the rotor pulley. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Diode HVAC > Component Information > Locations Compressor Clutch Diode HVAC: Locations Photo 19 - A/C Pressure Switch Left Front Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Diode HVAC > Component Information > Locations > Page 7487 Compressor Clutch Diode HVAC: Testing and Inspection Diode Test NOTE: The diodes are designed to pass current in one direction while blocking it in the opposite direction. Most ohmmeters, unless equipped with a diode tester, should not be used to test diodes. Check for continuity in both directions between the A and B terminals. There should be continuity in only one direction. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Photo 19 - A/C Pressure Switch Left Front Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 7491 Compressor Clutch Relay: Testing and Inspection Relay Test - There should be continuity between the C and D terminals. - There should be continuity between the A and B terminals when power and ground are connected to the C and D terminals. - There should be no continuity when power is disconnected. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Recalls for Condenser HVAC: > 96-010 > Sep > 08 > CAMPAIGN DISCONTINUATION NOTIFICATION Condenser HVAC: Recalls CAMPAIGN DISCONTINUATION NOTIFICATION 96-010 September 26, 2008 Applies To: 1994-95 Accord, Civic, Del Sol Product Update: Air Conditioning Condenser (Supersedes 96-010, dated April 1, 1996, to update the information shown with asterisks.) *This Product Update campaign has ended. Any repair cost is now the customer's responsibility.* Disclaimer Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Condenser HVAC: > 96-010 > Sep > 08 > CAMPAIGN DISCONTINUATION NOTIFICATION Condenser HVAC: All Technical Service Bulletins CAMPAIGN DISCONTINUATION NOTIFICATION 96-010 September 26, 2008 Applies To: 1994-95 Accord, Civic, Del Sol Product Update: Air Conditioning Condenser (Supersedes 96-010, dated April 1, 1996, to update the information shown with asterisks.) *This Product Update campaign has ended. Any repair cost is now the customer's responsibility.* Disclaimer Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Locations > Photo 17 Condenser Fan: Locations Photo 17 Right Front Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Locations > Photo 17 > Page 7509 Condenser Fan: Locations Photo 18 Left Front Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions Condenser Fan: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7512 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7513 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7514 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7515 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7516 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7517 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7518 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7519 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7520 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7521 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7522 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7523 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7524 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7525 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7526 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7527 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7528 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7529 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7530 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7531 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7532 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7533 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7534 Condenser Fan: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7535 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7536 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7537 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7538 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7539 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7540 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7541 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7542 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7543 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7544 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7545 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7546 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7547 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7548 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7549 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7550 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7551 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7552 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7553 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7554 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7555 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7556 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7557 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7558 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7559 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7560 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Page 7561 Condenser Fan: Description and Operation Voltage is provided at all times to the condenser fan relay (contacts) through fuse 35. With the ignition switch in ON (II), voltage is provided to the coil of the relay through fuse 13. When you push the A/C switch and put the heater fan switch in the 1, 2, 3 or 4 position and the A/C thermostat is ON, the condenser fan relay energizes, and the condenser fan motor runs. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Page 7562 Condenser Fan: Testing and Inspection Condenser Fan Flowchart Part 1 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Page 7563 Part 2 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan Diode > Component Information > Testing and Inspection Condenser Fan Diode: Testing and Inspection Diode Test NOTE: The diodes are designed to pass current in one direction while blocking it in the opposite direction. Most ohmmeters, unless equipped with a diode tester, should not be used to test diodes. Check for continuity in both directions between the A and B terminals. There should be continuity in only one direction. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Photo 19 Condenser Fan Motor Relay: Locations Photo 19 Photo 19 - A/C Pressure Switch Left Front Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Photo 19 > Page 7571 Condenser Fan Motor Relay: Locations Photo 31 Right Rear Corner Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Page 7572 Condenser Fan Motor Relay: Testing and Inspection Relay Test - There should be continuity between the C and D terminals. - There should be continuity between the A and B terminals when power and ground are connected to the C and D terminals. - There should be no continuity when power is disconnected. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Intake Air Temperature Sensor Control Assembly: Locations Intake Air Temperature Sensor Center Rear Of Engine Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Intake Air Temperature Sensor > Page 7577 Control Assembly: Locations Mode Control Motor Behind Dash, Right Of Steering Column Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Intake Air Temperature Sensor > Page 7578 Control Assembly: Locations Recirculation Control Motor Behind Glove Box Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions Control Assembly: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7581 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7582 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7583 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7584 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7585 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7586 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7587 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7588 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7589 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7590 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7591 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7592 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7593 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7594 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7595 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7596 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7597 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7598 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7599 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7600 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7601 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7602 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7603 Control Assembly: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7604 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7605 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7606 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7607 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7608 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7609 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7610 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7611 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7612 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7613 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7614 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7615 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7616 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7617 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7618 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7619 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7620 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7621 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7622 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7623 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7624 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7625 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7626 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7627 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7628 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7629 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Page 7630 Control Assembly: Description and Operation The air delivery system directs the flow of air used by the heater and air conditioner systems. Mode Selection Mode selection is controlled by the mode switches in the heater control panel and the mode control motor. When you select a specific mode, voltage is applied through the dimming circuit to the LED, which comes ON, indicating the mode selected. Ground is provided to the mode control motor through that mode switch. The motor then runs until the air control door reaches the proper position. Fresh/Recirculation Selection When you press the fresh or recirculation button, a ground signal is sent from the heater control panel to the recirculation control motor. The motor then runs until the recirculation door reaches the proper position. Battery voltage is also applied through the dimming circuit to the corresponding LED, and the LED comes ON. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing and Inspection > A/C Switch & Fan Switch Control Assembly: Testing and Inspection A/C Switch & Fan Switch A/C Switch Test Check for continuity between the terminals according to the table below. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing and Inspection > A/C Switch & Fan Switch > Page 7633 Control Assembly: Testing and Inspection Heater Fan Switch Test Heater Fan Switch Test Check for continuity between the terminals according to the table below. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing and Inspection > A/C Switch & Fan Switch > Page 7634 Control Assembly: Testing and Inspection Mode Control Motor Test Mode Control Motor Test 1. Connect battery power to the (1) terminal of the mode control motor and connect ground to the (2) terminal. 2. Using a jumper wire, short the (2) terminal individually to the (3), (4), (5), (6), and (7) terminals, in that order. ^ Each time the short circuit is made, the mode control motor should run smoothly and stop. NOTE: If the mode control motor does not run when shorting the first terminal, short that terminal again after shorting the other terminals. The mode control motor is normal if it runs when shorting the first terminal again. 3. If the mode control motor does not run in step 2, remove it, and check the mode control linkage and doors for smooth movement. If the mode control linkage and doors move smoothly, replace the mode control motor. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing and Inspection > A/C Switch & Fan Switch > Page 7635 Control Assembly: Testing and Inspection Mode Control Switch Test Mode Control Switch Test Check for continuity between the terminals according to the table below. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing and Inspection > A/C Switch & Fan Switch > Page 7636 Control Assembly: Testing and Inspection A/C Switch & Fan Switch A/C Switch Test Check for continuity between the terminals according to the table below. Heater Fan Switch Test Heater Fan Switch Test Check for continuity between the terminals according to the table below. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing and Inspection > A/C Switch & Fan Switch > Page 7637 Mode Control Motor Test Mode Control Motor Test 1. Connect battery power to the (1) terminal of the mode control motor and connect ground to the (2) terminal. 2. Using a jumper wire, short the (2) terminal individually to the (3), (4), (5), (6), and (7) terminals, in that order. ^ Each time the short circuit is made, the mode control motor should run smoothly and stop. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing and Inspection > A/C Switch & Fan Switch > Page 7638 NOTE: If the mode control motor does not run when shorting the first terminal, short that terminal again after shorting the other terminals. The mode control motor is normal if it runs when shorting the first terminal again. 3. If the mode control motor does not run in step 2, remove it, and check the mode control linkage and doors for smooth movement. If the mode control linkage and doors move smoothly, replace the mode control motor. Mode Control Switch Test Mode Control Switch Test Check for continuity between the terminals according to the table below. Recirculation Control Motor Test Recirculation Control Motor Test 1. Connect battery power to the (1) terminal of the recirculation control motor and connect ground to the (2) and (3) terminals; the recirculation control motor should run smoothly. 2. Disconnect ground from (2) or (3); the recirculation control motor should stop at FRESH or RECIRCULATE. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing and Inspection > A/C Switch & Fan Switch > Page 7639 CAUTION: Never connect the battery in the opposite direction. NOTE: Don't cycle the recirculation control motor for a long time. 3. If the recirculation control motor does not run in step 1, remove it, and check the recirculation control linkage and door for smooth movement. If the recirculation control linkage and door move smoothly, replace the recirculation control motor. Recirculation Control Switch Test Recirculation Control Switch Test Check for continuity between the terminals according to the table below. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Adjustments > Air Mix Control Cable Adjustment Control Assembly: Adjustments Air Mix Control Cable Adjustment Air Mix Control Cable Adjustment 1. Disconnect the heater valve cable from the heater valve. 2. Set the temperature control lever on COOL. 3. Turn the cable arm to the stop and connect the end of the air mix control cable to the cable arm. 4. Gently slide the air mix control cable outer housing back from the end enough to take up any slack in the air mix control cable, but not enough to make the temperature control lever move, then snap the air mix control cable housing into the cable clamp. NOTE: The heater valve cable should always be adjusted when ever the air mix control cable has been disconnected. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Adjustments > Air Mix Control Cable Adjustment > Page 7642 Control Assembly: Adjustments Heater Valve Cable Adjustment Heater Valve Cable Adjustment 1. Disconnect the heater valve cable from the heater valve. 2. Set the temperature control lever on COOL. 3. Turn the cable arm to the stop and connect the end of the heater valve cable to the cable arm. 4. Gently slide the heater valve cable outer housing back from the end enough to take up any slack in the heater valve cable, but not enough to make the temperature control lever move. Hold the end of the heater valve cable housing against the stop, then snap the heater valve cable housing into the cable clamp. 5. Turn the heater valve arm to shut and connect the end of the heater valve cable to the cable arm. 6. Gently slide the heater valve cable outer housing back from the end enough to take up any slack in the heater valve cable, but not enough to make the temperature control lever move, then snap the heater valve cable housing into the cable clamp. NOTE: The air mix control cable should always be adjusted when ever the heater valve cable has been disconnected. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Air Mix Control Control Assembly: Service and Repair Air Mix Control Removal and Installation Air Mix Control Cable Replacement 1. Cut the inner cable on the lever side of the cable holder, then remove both pieces of the inner cable. 2. Using a sharp knife, cut completely through the end of the cable housing at the two locations. 3. Slide the large section of the cable housing out of the cable holder, being careful not to damage the cable stoppers. 4. Carefully remove the cut pieces of the cable housing with a small flat tip screwdriver. 5. Hook the tip of the new air mix cable to the temperature control lever, then push the cable housing into the cable holder until it locks place. NOTE: After assembly, check that the temperature control lever slides smoothly through the full stroke from right to left. Overhaul Overhaul Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Air Mix Control > Page 7645 Control Assembly: Service and Repair Heater Control Panel Replacement 1. Remove the center lower cover. SRS wire harnesses are routed near the center lower cover. CAUTION: All SRS wire harnesses are covered with yellow insulation. Before you disconnect any part of an SRS wire harness, connect the short connectors. Whenever the ignition switch is ON (II), or has been turned OFF for less than three minutes, be careful not to bump the SRS unit; the airbags could accidentally deploy and cause damage or injuries. Disassemble in numbered sequence. General Precautions 1. Carefully inspect any SRS part before you install it. Do not install any part that shows signs of being dropped or improperly handled, such as dents, cracks or deformation: Airbag assemblies - Cable reel - SRS unit 2. Use only a digital multimeter to check the system. If it's not a Honda multimeter, make sure its output is 10 mA (0.01 A) or less when switched to the smallest value in the ohmmeter range. A tester with a higher output could damage the airbag circuit or cause accidental deployment and possible injury. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Air Mix Control > Page 7646 3. Do not install used SRS parts from another car. When making SRS repairs, use only new parts. 4. Except when performing electrical inspections, always disconnect both the negative cable and positive cable from the battery, and wait at least three minutes before beginning work. 5. Whenever the ignition switch is ON (II), or has been turned OFF for less than three minutes, be careful not to bump the SRS unit; the airbags could accidentally deploy and cause damage or injuries. 6. Whenever the airbag has been activated, replace the SRS unit. 7. The original radio has a coded theft protection circuit. Be sure to get the customer's code number before disconnecting the battery cables. Use only a digital multimeter to check the system. If it's not a Honda multimeter, make sure its output is 10 mA (0.01 A) or less when switched to the smallest value in the ohmmeter range. A tester with a higher output could damage the airbag circuit or cause accidental deployment and possible injury. 8. Do not install used SRS parts from another car. When making SRS repairs, use only new parts. 9. Whenever the ignition switch is ON (II), or has been turned OFF for less than three minutes, be careful not to bump the SRS unit; the airbags could accidentally deploy and cause damage or injuries. 10. Whenever the airbag has been activated, replace the SRS unit. 11. The original radio has a coded theft protection circuit. Be sure to get the customer's code number before disconnecting the battery cables. Airbag Handling and Storage Do not try to disassemble the airbag assembly. It has no serviceable parts. Once an airbag has been operated (deployed), it cannot be repaired or reused. For temporary storage of the airbag assembly during service, please observe the following precautions: 1. Store the removed airbag assembly with the pad surface up. If the airbag is improperly stored face down, accidental deployment could propel the unit with enough force to cause serious injury. 2. Store the removed airbag assembly on a secure flat surface away from any high heat source (exceeding 212°F/1OO°C) and free of any oil, grease, detergent or water. CAUTION: Improper handling or storage can internally damage the airbag assembly, making it inoperative. If you suspect the airbag assembly has been damaged, install a new unit and refer to the Deployment/Disposal Procedures for disposing of the damaged airbag. NOTE: Lift up the parking brake lever. Take care not to scratch the center and rear consoles and dashboard. CAUTION: When prying with a flat tip screwdriver, wrap it with protective tape to prevent damage. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Air Mix Control > Page 7647 NOTE: Do not drop the screws inside the dashboard. Take care not to bend the air mix control cable. CAUTION: When prying with a flat tip screwdriver, wrap it with protective tape to prevent damage. 3. Remove the radio/cassette player. NOTE: The original radio has a coded theft protection circuit. Be sure to get the customer's code number before - disconnecting the battery. - removing the No.32 (7.5 A) fuse from the underhood fuse/relay box. - removing the radio After service, reconnect power to the radio and turn it on. When the word "CODE" is displayed, enter the customer's 5-digit code to restore radio operation. CAUTION: During installing or replacement, avoid strong impacts in the area near the SRS unit. 4. Remove the center instrument panel, then disconnect the 4-P connector from the cigarette lighter. 5. Remove the two screws, then disconnect the 16-P connector and the antenna lead, and pull out the radio/cassette player. 6. Disconnect the air mix control cable from the heater unit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Air Mix Control > Page 7648 7. Disconnect the heater valve cable from the heater valve. 8. Set the temperature control lever on COOL. 9. Turn the cable arm to the stop and connect the end of the air mix control cable to the cable arm. 10. Gently slide the air mix control cable outer housing back from the end enough to take up any slack in the air mix control cable, but not enough to make the temperature control lever move, then snap the air mix control cable housing into the cable clamp. NOTE: The heater valve cable should always be adjusted when ever the air mix control cable has been disconnected. 11. Remove the three self-tapping screws. Disconnect the connectors and remove the heater control panel. NOTE: The locking tabs are on the bottom of the connectors. 12. Install in the reverse order of removal, and refer to Air Mix Control Cable Replacement. If necessary, adjust the heater valve cable. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Air Mix Control > Page 7649 Control Assembly: Service and Repair Mode Control Motor Replacement Mode Control Motor Replacement 1. Disconnect the mode control motor 8P connector and remove the female connector from the bracket. 2. Remove the two screws, the mode control motor and flange collar. 3. Install in the reverse order of removal. After installation, make sure the mode control motor operates smoothly. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Air Mix Control > Page 7650 Control Assembly: Service and Repair Recirculation Control Motor Replacement Recirculation Control Motor Replacement 1. Disconnect the 4P connector from the recirculation control motor and remove the wire harness holder. 2. Remove the two screws, the recirculation control motor and flange collar. 3. Install in the reverse order of removal. After installation, make sure the recirculation control motor operates smoothly. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions Control Module HVAC: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7655 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7656 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7657 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7658 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7659 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7660 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7661 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7662 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7663 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7664 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7665 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7666 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7667 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7668 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7669 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7670 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7671 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7672 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7673 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7674 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7675 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7676 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7677 Control Module HVAC: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7678 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7679 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7680 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7681 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7682 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7683 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7684 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7685 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7686 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7687 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7688 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7689 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7690 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7691 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7692 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7693 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7694 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7695 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7696 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7697 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7698 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7699 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7700 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7701 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7702 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7703 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Removal and Installation Evaporator Core: Service and Repair Removal and Installation 1. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. 2. Disconnect both ground and positive battery cables, then remove battery. 3. Discharge A/C system. 4. Remove bolts and disconnect receiver and suction lines from evaporator and plug lines. 5. Remove glove compartment and frame. 6. Disconnect electrical connector from A/C thermostat, then remove clips or clamps from evaporator. Fig. 24 Evaporator Housing Removal 7. Remove self-tapping screws, bolts and nut, Fig. 24. 8. Disconnect drain hose and remove evaporator. 9. Pull evaporator sensor from evaporator fins. 10. Remove self-tapping screws and clips from housing. 11. Separate housings, then remove evaporator covers. 12. Remove expansion valve, if necessary. When loosening expansion valve nuts, use second wrench to hold valve or evaporator pipe to avoid damaging them. 13. Reverse procedure to install, noting the following: a. Use new O-rings when installing expansion valve and connecting refrigerant lines. b. Install expansion valve and secure valve sensor against suction line with tape. c. Reinstall evaporator sensor in its original location. d. Ensure there is no air leakage in evaporator housing. 14. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Removal and Installation > Page 7708 Evaporator Core: Service and Repair Overhaul Evaporator Overhaul 1. Pull the A/C thermostat sensor out of the evaporator fins. 2. Remove the self-tapping screws and clips from the housing. 3. Carefully separate the housings, and remove the evaporator covers. 4. Remove the expansion valve if necessary. NOTE: When loosening the expansion valve nuts, use a second wrench to hold the expansion valve or evaporator pipe, otherwise, they can be damaged. - Assemble in the reverse order of disassembly, and: ^ Replace the all 0-rings with new ones at each fitting, and apply a thin coat of refrigerant oil (SP-10: P/N 38899-P13-AO 1) before installing them. NOTE: Be sure to use the right 0-rings for HFC-134a (R-134a) to avoid leakage. ^ Install the expansion valve capillary tube with the capillary tube in contact with the suction line directly, and wrap it with tape. ^ Reinstall the A/C thermostat sensor to its original location. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations Evaporator Temperature Sensor / Switch: Locations Behind Glove Box Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 7712 Evaporator Temperature Sensor / Switch: Description and Operation The A/C thermostat is located on the evaporator housing. The A/C thermostat turns OFF the A/C compressor clutch if the temperature at the evaporator goes below 3°C (37°F). This prevents condensation from freezing on the evaporator fins and blocking the air delivery into the passenger compartment. If the temperature goes below 3°C (37°F) turning OFF the A/C thermostat, ground will be removed from the condenser fan relay. The relay will deenergize removing voltage from the condenser fan motor causing it to stop running. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 7713 Evaporator Temperature Sensor / Switch: Testing and Inspection A/C Thermostat Test Connect battery power to terminal C and ground terminal B, and connect a test light between terminals A and C. NOTE: Use a 12 V, 3 W - 18 W test light. Dip the A/C thermostat into a cup filled with ice water, and check the test light. The light should go off at 37°F (3°C) or less, and should come on at 39°F (4°C) or more. If the light doesn't come on and go off as specified, replace the A/C thermostat. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair Expansion Valve: Service and Repair 1. Disconnect battery ground cable and discharge A/C system using refrigerant recovery equipment. 2. Disconnect receiver and suction lines from evaporator and plug lines. 3. Remove glove box and frame. 4. Disconnect electrical connector from thermostat switch. Fig. 22 Removing Evaporator Housing Supports 5. Remove self-tapping screws and bands, Fig. 22. Fig. 23 Evaporator Housing Removal 6. Remove mounting bolts and evaporator housing, Fig. 23. 7. Remove evaporator sensor from the evaporator fins. 8. Separate housings, then remove evaporator cover. 9. The expansion valve can be removed after the evaporator has been lifted out of the case. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair > Page 7717 9. Reverse procedure to install, noting the following: a. Use new O-rings when installing expansion valve and connecting refrigerant lines. b. Install expansion valve and secure valve sensor against suction line with tape. c. Reinstall evaporator sensor in its original location. d. Ensure there is no air leakage in the evaporator housing. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Control Valve > Heater Control Valve Cable > Component Information > Technical Service Bulletins > A/C - Heater Blows Cold Air/A/C Blows Hot Air Heater Control Valve Cable: Technical Service Bulletins A/C - Heater Blows Cold Air/A/C Blows Hot Air Heater Blows Cold Air; A/C Blows Warm Air NOTE: This article applies to all A/C-equipped Honda models that use a heater valve cable. Got a vehicle in your shop that blows cold air from the heater or warm air from the A/C? The problem could just be the heater valve cable has slipped off the heater valve arm. There's a real easy fix for this problem. Slip the heater valve cable back onto the heater valve arm. Then cut yourself a 10 mm length of 3.5 mm vacuum hose (P/N 95005-35008-10M, H/C 2325058), and slide it onto the arm. This holds the cable on the arm nice and snug so it won't slip off. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Control Valve > Heater Control Valve Cable > Component Information > Technical Service Bulletins > A/C - Heater Blows Cold Air/A/C Blows Hot Air > Page 7723 Heater Control Valve Cable: Technical Service Bulletins A/C - Heater Blows Cold Air, A/C Blows Warm Air SOURCE: Honda Service News TITLE: Heater Blows Cold Air, A/C Blows Warm Air APPLIES TO: all A/C-equipped Honda models that use a heater valve cable. SERVICE TIP: Got a vehicle in your shop that blows cold air from the heater or warm air from the A/C ? The problem could just be the heater valve cable has slipped off the heater valve arm. There's a real easy fix for this problem. Slip the heater valve cable back onto the heater valve arm. Then cut yourself a 10 mm length of 3.5 mm vacuum hose and slide it onto the arm. This holds the cable on the arm nice and snug so it won't slip off. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Diagrams > Diagram Information and Instructions Heater Core: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 7728 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 7729 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 7730 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 7731 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 7732 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 7733 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 7734 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 7735 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 7736 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 7737 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 7738 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 7739 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 7740 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 7741 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 7742 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 7743 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 7744 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 7745 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 7746 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 7747 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 7748 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 7749 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 7750 Heater Core: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 7751 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 7752 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 7753 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 7754 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 7755 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 7756 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 7757 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 7758 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 7759 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 7760 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 7761 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 7762 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 7763 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 7764 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 7765 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 7766 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 7767 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 7768 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 7769 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 7770 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 7771 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 7772 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 7773 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 7774 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 7775 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Diagrams > Diagram Information and Instructions > Page 7776 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Diagrams > Page 7777 Heater Core: Service and Repair 1. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. 2. Disconnect battery ground cable, then drain cooling system. 3. Snap open cable clip, then disconnect heater valve cable from heater valve. 4. Disconnect heater hoses at heater, then remove heater unit mounting nut from engine compartment side. 5. Remove instrument panel. 6. Remove heat duct or evaporator and steering column bracket. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Diagrams > Page 7778 7. Remove clip, heater mounting nuts and heater assembly. Fig. 16 Heater Core Removal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Diagrams > Page 7779 8. Remove heater core cover attaching screws, then the cover, Fig. 16. 9. Remove pipe clamp and damper arm attaching screws. 10. Pull heater core from heater housing. Ensure care is taken not to bend inlet and outlet pipes during removal. 11. Reverse procedure to install, noting the following: a. Do not interchange inlet and outlet hoses. b. Connect all cables and ensure they are properly adjusted. 12. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. 13. After refilling cooling system, bleed cooling system. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Service and Repair High Pressure Safety Valve HVAC: Service and Repair Relief Valve Replacement Removal NOTE: Make sure the suction and discharge ports are plugged with caps. 1. Remove the relief valve cover, relief valve, and 0-ring. NOTE: Be sure to use the right 0-rings for HFC-134a (R-134a) to avoid leakage. CAUTION: Be careful not to spill compressor oil, and make sure there is no foreign matter in the system. Installation 1. Clean off the relief valve mating surface. 2. Replace the relief valve 0-ring with a new one and apply a thin coat of refrigerant oil (SP-1O: P/N 38899-P13-AO1) before installing it. NOTE: ^ To avoid contamination, do not return the oil to the container once dispensed and never mix it with other refrigerant oils. ^ Immediately after using the oil, replace the cap on the container, and seal it to avoid moisture absorption. ^ Do not spill the refrigerant oil on the car; it may damage the paint; if the refrigerant oil contacts the paint, wash it off immediately. 3. Tighten the relief valve. 4. Put the cover on the relief valve so that the arrow points downwards as shown above. 5. Check the relief valve for leaks. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Leak Detection Refrigerant: Technical Service Bulletins A/C - Refrigerant Leak Detection 07-030 October 12, 2007 Applies To: ALL Vehicles With Conventional A/C Compressors A/C Leak Detection (Supersedes 07-030, dated June 15, 2007, to update the information marked by asterisks) The OPTIMAX Jr. (TM)A/C Leak Detection Kit for Honda vehicles, P/N TRP124893, is a new required tool. The kit is used to add small amounts of dye to A/C systems to help locate smaller leaks that an electronic leak detector might not find. When searching for leaks, always begin by using an electronic leak detector. Refer to Service Bulletin 97-027, Denso HLD-100 Halogen Leak Detector; for tips on using this tool, then follow up with the OPTIMAX Jr. This new detection kit complements but does not replace the electronic detector. The kit contains: ^ TRP8640CS, OPTIMAX Jr. (TM) cordless, fluorescent leak detection flashlight lamp (includes 3 standard AA batteries) ^ TRP38600601, (6) 0.06 oz. (1.7 g) Tracer-Stick(R) R134a/PAG A/C dye capsules with ID labels ^ TRP3887, R-134a Universal Connect Set(TM) ^ TRP120884, GLO-AWAY(TM) dye cleaner ^ TRP9940, fluorescence-enhancing glasses ^ TRP1143, (1) empty Tracer-Stick dye capsule ORDERING INFO *One OPTIMAX Jr. A/C Leak Detection Kit was shipped to each current dealer as a required special tool. Additional kits and replacement capsules may be ordered through the Honda Tool and Equipment Program. On the iN, click on Service, Service Bay, Tool and Equipment Program, Online Catalog tab, and Air Conditioning Equipment, or call.* NOTICE ^ Do not use leak-trace dye in any Honda hybrid vehicle equipped with a dual-scroll compressor This can increase the chance of electric shock. The compressor is easily identified by the orange high-voltage cable that is connected to the compressor body. ^ Only Tracer-Stick single-dose fluorescent dye capsules from Tracer Products (Tracerline(R)) are approved for use in Honda vehicles. Other dyes contain solvents that may contaminate the system's refrigerant oil, leading to component failure. ^ Adding excessive amounts of dye can lead to compressor damage and failure. USING THE OPTIMAX JR. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Leak Detection > Page 7787 1. Before adding any leak-detection dye, check to see if there is dye in the system now. ^ Check for a label in the engine compartment indicating that fluorescent leak-detection dye has been added to the system. ^ Dye may have been added even though no label is present. To confirm this: - Put on the fluorescence-enhancing glasses, and remove the low-side service port sealing cap. - Direct the ultraviolet lamp into the valve stem area. If dye has been previously added, the lubricant traces will have a bright yellow fluorescent glow. You may need to press the port's valve stem briefly to release some lubricant and dye from the system. ^ If there is no dye in the system, go to step 2. ^ If there is dye in the system, go to step 5. Do not add more dye. 2. Add the dye. NOTE: Air and moisture must be evacuated from the universal connect set if it is being used for the first time, or if it has been stored with the control valve open. If the air and moisture have been evacuated, go to step 3; otherwise do the following: (a) Attach the empty dye capsule (provided in the dye kit) to the control valve fitting. (b) Attach the service valve fitting (provided in the kit) to the empty dye capsule. (c) Attach the low-side hose of the A/C recovery and charging station, and open the quick coupler's hand-wheel valve. Then open the control valve (black knob) on the universal connect set. (d) Following the manufacturer's instructions for your recovery and charging station, evacuate the universal connect set for approximately 3 minutes. (e) When evacuation is complete, be sure the set's control valve is closed (finger tight), and disconnect the NC recovery and charging station. (f) Remove the service valve fitting and the empty dye capsule from the set, and store them for future use. NOTE: ^ Check the refrigerant charge level. There must be enough refrigerant in the system to operate the A/C compressor and to circulate refrigerant oil. ^ If the refrigerant charge is too low, recover the remaining amount and recharge the system before adding any dye. (g) Start the vehicle and operate the A/C system. Follow your A/C refrigerant recovery and charging station's operating instructions for low-side charging to install the dye. * NOTE: Only 0.05 lb (0.02 kg) of refrigerant is needed to push the dye into the A/C system.* (h) Once the refrigerant charge is programmed, open the control valve on the set to allow the dye to enter the system. (i) After the dye capsule clears, allow the low-side of the A/C system to reach its lowest operating pressure, then quickly close both the service equipment's low-side coupler valve and the control valve on the set. (j) Remove the set from the vehicle by releasing its quick coupler. Remove the empty dye capsule from the service valve fitting. Return the hose, control valve, and service-valve fitting to the storage case. * NOTE: Store the hose with the control valve closed. This will retain a small amount of refrigerant in the hose so it does not have to be evacuated the next time you use it.* (k) Fill out an identification label (provided in the kit), and attach it to a location near the A/C charge label. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Leak Detection > Page 7788 3. Connect the universal connect set and the Tracer- Stick dye capsule: (a) Be sure the quick coupler and control valves on the set are closed. (b) Remove the low-side service port sealing cap, and connect the set to the low-side service port using the quick coupler. (c) Hold a new dye capsule so that the embossed arrow is pointing up. Remove the black end cap, and carefully attach the capsule to the control valve fitting. NOTE: The capsule must be held with the embossed arrow pointing up or the dye will leak out of the capsule. (d) Turn the capsule so the embossed arrow is pointing down. Remove the orange end cap, and carefully attach the service valve fitting provided in the kit (finger tight). NOTE: The capsule must be held with the embossed arrow pointing down or the dye will leak out. 4. Connect the NC service equipment: With the universal connect set and dye capsule attached to the vehicle's low-side service port, connect the A/C refrigerant recovery and charging station's low-side hose quick coupler to the service valve fitting. Open the blue hand-wheel valves on both quick couplers. Leave the control valve (black knob) on the universal connect set closed. NOTE: * ^ If you have recovered refrigerant to weigh it as part of your diagnostics, or if there is a low charge, it is more efficient to recharge the system using normal procedures before installing the universal connect set. Dye can then be added using approximately 0.05 lb (0.02 kg) of refrigerant.* ^ You do not need to connect the service equipment's high-side hose to the vehicle to install the dye. If the high-side hose is connected, make sure its coupler valve is closed before proceeding. ^ Do not use the A/C recovery and charging station to recover or evacuate the A/C system when a full dye capsule is attached. The dye will be drawn into the service equipment instead of being added to the vehicle's A/C system. 5. Inspect the A/C system for leaks: (a) Run the A/C system for at least 15 minutes to circulate the dye through the system. Large leaks will be seen immediately as a fluorescent yellow glow. Smaller leaks may require at least 24 hours of vehicle operation before they become visible. Operate the A/C system as much as possible during this time to keep the dye circulating. (b) Stop the vehicle's engine and inspect the system for leaks using the ultraviolet (UV) lamp and fluorescence-enhancing glasses from the kit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Leak Detection > Page 7789 Low ambient light conditions (a dark work area) will aid in locating the leak. NOTE: Not all UV lamps work well with all types of fluorescent dye. Use only the lamp provided in the kit to inspect for leaks. (c) Inspect the entire system. Be sure to check these locations: ^ damaged and corroded areas ^ fittings ^ hose-to-line couplings ^ refrigerant controls ^ service ports ^ brazed or welded areas ^ areas near attachment points (d) Check for evaporator leaks by illuminating the evaporator drain tube area with the UV lamp and glasses. (e) After repairing a leak, remove any fluorescent residue using the GLO-AWAY dye cleaner from the kit and hot water (follow the instructions on the bottle). Disclaimer Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Refrigerant: Capacity, Lbs. ...................................................................................................................................... ................................................................... 1.2 Type ........................................................................... ....................................................................................................................................... R-134a Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 7792 Refrigerant: Fluid Type Specifications A/C Refrigerant .................................................................................................................................... ...................................................................... R-134a Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Refrigerant Oil Type: SP-10: P/N 38899-P13-AO1 Refrigerant Oil Capacity: Condenser: 20 ml (2/3 fl.oz, 0.7 imp.oz) Evaporator: 45 ml (1 1/2 fl.oz, 1.6 imp.oz) Line or hose: 10 ml (1/3 fl.oz, 0.4 imp.oz) Receiver/Dryer: 10 ml (1/3 fl.oz, 0.4 imp.oz) Leakage repair: 25 ml (5/6 fl.oz, 0.9 imp.oz) Compressor: For compressor replacement, subtract the volume of oil drained from the removed compressor from 120 ml (4 fl.oz, 4.2 imp.oz), and drain the calculated volume of oil from the new compressor. 120 ml (4 fl.oz, 4.2 imp.oz) - Volume of removed compressor = Volume to drain from new compressor. NOTE: Even if no oil is drained from the removed compressor, don't drain more than 50 ml (1 2/3 fl.oz, 1.8 imp.oz) from the new compressor. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 7797 Refrigerant Oil: Fluid Type Specifications Refrigerant Oil Type ............................................................................................................................ ......................................................................... SP-10 Honda PN ....................................................... ........................................................................................................................................ 38897-P13-A01AH Honda Code ......................................................................................................... .................................................................................................... 5023627 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations Refrigerant Pressure Sensor / Switch: Locations Photo 19 - A/C Pressure Switch Left Front Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 7801 Refrigerant Pressure Sensor / Switch: Description and Operation Battery voltage is supplied through fuse 35 to the A/C compressor clutch relay contacts at all times. With the ignition switch in ON (II), voltage is applied to the coil of the A/C compressor clutch relay through fuse 13. When you push the A/C switch ON, and the heater fan switch is in position 1, 2, 3, or 4, a "ground" input is provided to the engine control module (ECM) through the A/C thermostat and the A/C pressure switch. The A/C compressor clutch relay is grounded by the engine control module (ECM). When energized, the A/C compressor clutch relay allows battery voltage to turn on the A/C compressor clutch. The A/C ON indicator light comes on when the A/C system is requested. The A/C pressure switch is located in the condenser outlet line where refrigerant is in a high temperature/high pressure liquid state. The switch will sense abnormally high or low pressure, and open the circuit. This removes ground, and the compressor will stop running. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations Blower Motor Relay: Locations Right Rear Corner Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 7806 Blower Motor Relay: Testing and Inspection Relay Test - There should be continuity between the C and D terminals. - There should be continuity between the A and B terminals when power and ground are connected to the C and D terminals. - There should be no continuity when power is disconnected. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Photo 19 - A/C Pressure Switch Left Front Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 7810 Compressor Clutch Relay: Testing and Inspection Relay Test - There should be continuity between the C and D terminals. - There should be continuity between the A and B terminals when power and ground are connected to the C and D terminals. - There should be no continuity when power is disconnected. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Photo 19 Condenser Fan Motor Relay: Locations Photo 19 Photo 19 - A/C Pressure Switch Left Front Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Photo 19 > Page 7815 Condenser Fan Motor Relay: Locations Photo 31 Right Rear Corner Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Page 7816 Condenser Fan Motor Relay: Testing and Inspection Relay Test - There should be continuity between the C and D terminals. - There should be continuity between the A and B terminals when power and ground are connected to the C and D terminals. - There should be no continuity when power is disconnected. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions Control Module HVAC: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7821 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7822 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7823 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7824 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7825 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7826 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7827 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7828 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7829 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7830 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7831 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7832 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7833 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7834 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7835 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7836 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7837 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7838 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7839 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7840 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7841 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7842 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7843 Control Module HVAC: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7844 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7845 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7846 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7847 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7848 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7849 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7850 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7851 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7852 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7853 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7854 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7855 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7856 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7857 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7858 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7859 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7860 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7861 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7862 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7863 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7864 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7865 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7866 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7867 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7868 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7869 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Air Conditioning Switch > Component Information > Testing and Inspection Air Conditioning Switch: Testing and Inspection A/C Switch Test Check for continuity between the terminals according to the table below. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions Blower Motor Switch: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7878 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7879 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7880 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7881 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7882 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7883 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7884 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7885 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7886 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7887 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7888 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7889 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7890 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7891 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7892 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7893 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7894 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7895 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7896 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7897 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7898 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7899 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7900 Blower Motor Switch: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7901 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7902 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7903 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7904 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7905 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7906 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7907 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7908 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7909 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7910 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7911 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7912 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7913 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7914 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7915 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7916 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7917 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7918 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7919 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7920 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7921 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7922 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7923 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7924 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7925 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7926 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Page 7927 Blower Motor Switch: Testing and Inspection Heater Fan Switch Test Check for continuity between the terminals according to the table below. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations Evaporator Temperature Sensor / Switch: Locations Behind Glove Box Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 7931 Evaporator Temperature Sensor / Switch: Description and Operation The A/C thermostat is located on the evaporator housing. The A/C thermostat turns OFF the A/C compressor clutch if the temperature at the evaporator goes below 3°C (37°F). This prevents condensation from freezing on the evaporator fins and blocking the air delivery into the passenger compartment. If the temperature goes below 3°C (37°F) turning OFF the A/C thermostat, ground will be removed from the condenser fan relay. The relay will deenergize removing voltage from the condenser fan motor causing it to stop running. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 7932 Evaporator Temperature Sensor / Switch: Testing and Inspection A/C Thermostat Test Connect battery power to terminal C and ground terminal B, and connect a test light between terminals A and C. NOTE: Use a 12 V, 3 W - 18 W test light. Dip the A/C thermostat into a cup filled with ice water, and check the test light. The light should go off at 37°F (3°C) or less, and should come on at 39°F (4°C) or more. If the light doesn't come on and go off as specified, replace the A/C thermostat. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations Refrigerant Pressure Sensor / Switch: Locations Photo 19 - A/C Pressure Switch Left Front Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 7936 Refrigerant Pressure Sensor / Switch: Description and Operation Battery voltage is supplied through fuse 35 to the A/C compressor clutch relay contacts at all times. With the ignition switch in ON (II), voltage is applied to the coil of the A/C compressor clutch relay through fuse 13. When you push the A/C switch ON, and the heater fan switch is in position 1, 2, 3, or 4, a "ground" input is provided to the engine control module (ECM) through the A/C thermostat and the A/C pressure switch. The A/C compressor clutch relay is grounded by the engine control module (ECM). When energized, the A/C compressor clutch relay allows battery voltage to turn on the A/C compressor clutch. The A/C ON indicator light comes on when the A/C system is requested. The A/C pressure switch is located in the condenser outlet line where refrigerant is in a high temperature/high pressure liquid state. The switch will sense abnormally high or low pressure, and open the circuit. This removes ground, and the compressor will stop running. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Thermal Limiting Fuse > Component Information > Locations Thermal Limiting Fuse: Locations Photo 3 - A/C Compressor Thermal Protector Left Front Corner Of Engine Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Thermal Limiting Fuse > Component Information > Locations > Page 7940 Thermal Limiting Fuse: Description and Operation Battery voltage is supplied through fuse 35 to the A/C compressor clutch relay contacts at all times. With the ignition switch in ON (II), voltage is applied to the coil of the A/C compressor clutch relay through fuse 13. When you push the A/C switch ON, and the heater fan switch is in position 1, 2, 3, or 4, a "ground" input is provided to the Engine Control Module (ECM) through the A/C thermostat and the A/C pressure switch. The A/C compressor clutch relay is grounded by the Engine Control Module (ECM). When energized, the A/C compressor clutch relay allows battery voltage to turn ON the A/C compressor clutch. The A/C ON indicator light comes ON when the A/C system is requested. The thermal protector, located on the A/C compressor, opens and turns the compressor OFF if it senses high temperature. Once the compressor cools, the switch will close and the compressor will begin running again. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Heating and Air Conditioning > Thermal Limiting Fuse > Component Information > Locations > Page 7941 Thermal Limiting Fuse: Service and Repair Thermal Protector Replacement 1. Remove the bolt, ground terminal, and connector holder. 2. Remove the thermal protector. Remove the residue of silicone sealant from the top of the thermal protector. 3. Apply silicone sealant to the top of the thermal protector. 4. Install in the reverse order of removal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Specifications Air Bag(s) Arming and Disarming: Specifications Component .......................................................................................................................................... ....................................................... Torque/Ft. Lbs. Dash Sensor Mounting Bolts .............................. .............................................................................................................................................................. .. 16 Driver Side Air Bag Assembly To Steering Wheel Bolts ................................................................................................................................................. 7.2 Passenger Side Air Bag Mounting Nuts & Bolts .................................................................................. ............................................................................. 7.2 SRS Unit Mounting Bolts ................................. .............................................................................................................................................................. .. 7.2 Steering Wheel To Column Steering Shaft Nut .......................................................................... ....................................................................................... 36 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Specifications > Page 7947 Air Bag(s) Arming and Disarming: Service Precautions 1. On models with 3-P SRS connectors, install red short connectors on air bags prior to disconnecting any part of SRS wiring harness. 2-P SRS connectors automatically short when disconnected. 2. Always use test harnesses. Do not use test probes directly on component connector pins or wires. 3. When connecting any test harnesses, push connectors straight in until secure. Do not bend connector pins. 4. Always keep red short connector on air bag connector when harness is disconnected. 5. Always store air bag assembly with pad surface facing upward. 6. Do not attempt to disassemble air bag assembly. 7. An air bag that has been deployed cannot be repaired or reused. 8. Keep air bag assembly free of oil and grease. 9. Do not expose air bag assembly to temperatures above 212°F. 10. Do not use SRS components from another vehicle. Always install new replacement components. 11. Do not paint air bag assembly to correct cosmetic flaws. It must be replaced. 12. Inspect all components prior to installation. Do not install any that appear to have been improperly handled or stored or that show any signs of damage. 13. When repairing vehicle, system should be disarmed as outlined under Technician Safety Information. 14. When performing service procedures, do not expose sensors or wiring or other SRS components to heat guns, welding or spray guns. 15. SRS wiring should not be spliced, soldered or repaired. 16. Use only special digital multimeter tool No. KS-AHM-32-003, or equivalent, digital multimeter with 0.0 mA or smaller output when switched to lowest ohmmeter range to inspect system. Analog or testers with higher outputs can damage circuits or cause accidental air bag deployment and, if equipped, seat belt pretensioner activation. 17. Do not bump SRS unit whenever ignition is turned On, or has been Off for less than three minutes. Unwanted deployment could result. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Specifications > Page 7948 Air Bag(s) Arming and Disarming: Service and Repair The Supplemental Restraint System (SRS) must be disarmed prior to disconnecting any electrical connectors or servicing any system components or items located near SRS electrical connectors. SRS electrical wiring can be identified by its yellow outer protective coating. To disarm the SRS, proceed as follows: 1. Obtain five-digit radio theft protection code number. 2. Disconnect battery ground cable, then the positive cable. Fig. 1 Driver Air Bag Disarming 3. After disconnecting cables, wait at least three minutes with ignition turned Off before disconnecting any SRS electrical connectors. This will allow air bag system back-up circuit capacitor to discharge. 4. Remove steering wheel access panel and disconnect electrical connector located between air bag and cable reel, Fig. 1 5. Remove glove compartment and access panel. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Specifications > Page 7949 Fig. 4 Passenger Air Bag Disarming 6. Disconnect front passenger air bag 3-P connector from SRS main harness and connect red short connector, Fig. 4. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Specifications > Page 7950 Fig. 12 Fuse Panel/SRS Connector 7. Using thin blade screwdriver, lift SRS to under-instrument panel fuse connector lid, Fig. 12, then press tab down and slide connector out. 8. Reverse procedure to reactivate system, noting following: a. Slide harness electrical connector onto fuse panel connections until it clicks, then close connector lid. b. Ensure all red short connectors have been removed and placed in their holders. c. Prior to connecting battery ground and positive cables, ensure all supplemental restraint system electrical connectors have been properly connected. d. After battery cables have been connected, turn ignition switch to On position. SRS indicator lamp should light for approximately six seconds. If lamp does not light or remains on longer than six seconds, A SYSTEM MALFUNCTION IS INDICATED. Refer to Testing and Inspection / Procedures See: Testing and Inspection/Initial Inspection and Diagnostic Overview e. Turn radio control to On. When word Code appears on display panel, enter five-digit theft protection code number. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Airbag Replacement Air Bag: Service and Repair Driver Airbag Replacement WARNING: Prior to disconnecting any Supplemental Restraint System (SRS) electrical connectors or servicing any system components or other components located near a SRS electrical connector, the SRS must be disarmed. Refer to Technician Safety Information. SRS electrical wiring can be identified by a yellow outer protective coating. Store a removed air bag assembly with the pad surface up. If the air bag is stored face down, accidental deployment could propel the unit with enough force to cause serious injury. REMOVAL 1. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. 2. Disconnect battery negative cable, then positive cable. Fig. 24 Driver Side Air Bag Mounting 3. Remove two air bag assembly attaching bolts, then the air bag assembly, Fig. 24. INSTALLATION 1. Position driver side air bag assembly to steering wheel, then install the two attaching bolts. Tighten attaching bolts to specifications. 2. Reconnect battery positive cable, then negative cable. 3. After completing installation, place ignition switch in On position. SRS indicator lamp should be illuminated for approximately six seconds, then lamp should turn off. If lamp remains illuminated or does not illuminate, a problem in the SRS is indicated. 4. If vehicle is equipped with radio theft protection, place radio control knob in On position. When the word Code appears on the radio display panel, enter the five-digit radio theft protection code number. Turn ignition switch On and observe instrument panel SRS indicator light. It should come On for approximately six seconds, then turn Off. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Airbag Replacement > Page 7955 Air Bag: Service and Repair Passenger Airbag Replacement REMOVAL 1. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. 2. Disconnect battery negative cable, then positive cable. 3. Remove glove compartment and access panel. 4. Remove six air bag assembly mounting nuts. Fig. 28 Passenger Side Air Bag Mounting 4. Carefully lift air bag assembly from instrument panel, Fig. 28. INSTALLATION 1. Position the air bag assembly in the instrument panel, then install six mounting nuts, Fig. 28. Do not tighten the mounting nuts at this time. 2. Tighten the upper four mounting nuts, then the two lower mounting nuts to specifications. The lower mounting brackets are adjustable and can be used to properly position the air bag assembly. 3. Install the access panel and glove compartment. 4. Reconnect battery positive cable, then negative cable. 5. After completing installation, place ignition switch in On position. SRS indicator lamp should be illuminated for approximately six seconds, then lamp should turn off. If lamp remains illuminated or does not illuminate, a problem in the SRS is indicated. 6. If vehicle is equipped with radio theft protection, place radio control knob in On position. When the word Code appears on the radio display panel, enter the five-digit radio theft protection code number. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Airbag Replacement > Page 7956 Air Bag: Service and Repair Airbag Assembly Disposal and Deployment When handling a deployed air bag assembly, a face shield and rubber gloves should be worn. Vehicle interior and A/C, vent, defroster and heater ducts should be vacuumed. If sinus or throat irritation is encountered during air bag removal, exit vehicle and breathe fresh air. If skin irritation is encountered, flush effected area with cool water. If sinus, throat, skin or any other type of irritation continues, consult a physician. After handling a deployed air bag assembly, wash hands and rinse thoroughly with water. An air bag that has been deployed should be removed from the vehicle. Prior to removing a deployed air bag assembly, place tape over air bag exhaust vents. After unit has been removed, it should be placed in a heavy duty plastic bag and sealed securely. The sealed plastic bag should then be placed with automotive scrap. An air bag assembly that has not been deployed, must be deployed prior to disposal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module: Locations Right Side Of Driver's Footwell Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 7960 Air Bag Control Module: Service and Repair 1. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. 2. Disconnect battery negative cable, then positive cable. 3. Pull down carpeting from both sides of front console and remove harness protector. 4. Disconnect SRS control unit connector. 5. Remove four SRS control unit mounting bolts, then control unit from vehicle. 6. Reverse procedure to install, noting the following: a. Tighten attaching bolts to specifications. b. After completing installation, place ignition switch in On position. SRS indicator lamp should be illuminated for approximately six seconds, then lamp should turn off. If lamp remains illuminated or does not illuminate, a problem in the SRS is indicated. 7. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations Clockspring Assembly / Spiral Cable: Locations Bottom Of Steering Wheel Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations > Page 7964 Clockspring Assembly / Spiral Cable: Service and Repair Store a removed air bag assembly with the pad surface up. If the air bag is stored face down, accidental deployment could propel the unit with enough force to cause serious injury. REMOVAL 1. Disconnect battery negative cable, then positive cable. 2. Ensure front wheels are aligned straight forward. 3. Remove lower cover and driver side knee bolster. 5. Remove driver side air bag. 6. Disconnect horn and cruise control electrical connectors. 7. Remove cable reel 3-P electrical from clip. 8. Remove steering wheel nut and steering wheel. 9. Remove steering column covers. Fig. 31 Cable Reel Replacement 9. Disconnect cable reel 6-P electrical connector, then remove connector holder, Fig. 31. 10. Remove the cable reel and canceling sleeve from the steering column. INSTALLATION Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations > Page 7965 Fig. 32 Aligning Able Reel & Cancelling Sleeve Projections 1. Align canceling sleeve grooves and cable reel projections, Fig. 32. 2. Install the cable reel to steering column. 3. Install cable reel 6-P electrical connector holder, Fig. 31. 4. Install steering column covers. Fig. 33 Centering Cable Reel 5. Center the cable reel by rotating clockwise until stop is contacted. Rotate the cable reel counterclockwise, approximately two turns, until yellow Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations > Page 7966 gear tooth is aligned with mark on cover and arrow mark on cable reel cover is pointing straight upward, Fig. 33. 6. Ensure front wheels are in the straight ahead position, then position steering wheel on steering shaft. 7. Attach cable reel 3-P electrical connector to clip. 8. Connect the horn and cruise control electrical connectors. 9. Install and tighten steering wheel retaining nut to specifications. 10. Install the driver side air bag assembly. 11. Place ignition switch in On position. SRS indicator lamp should be illuminated for approximately six seconds, then lamp should turn off. If lamp remains illuminated or does not illuminate, a problem in the SRS is indicated. 12. If vehicle is equipped with radio theft protection, place radio control knob in On position. When the word Code appears on the radio display panel, enter the five-digit radio theft protection code number. Turn ignition switch on and observe instrument panel SRS indicator light. It should come on for approximately six seconds, then turn off. Fig. 34 Cable Reel Alignment 13. After installation is complete, double check cable reel installation by rotating steering wheel counterclockwise until yellow gear tooth lines up with slot on cover, Fig. 34. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Diagnostic Connector, Air Bag > Component Information > Locations Diagnostic Connector: Locations Behind Left Side Of Dash Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair Impact Sensor: Service and Repair 1. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. 2. Remove footrest and left door sill molding, then pull back carpet. Fig. 35 Dash Sensor Mounting 3. Remove dash sensor protector, then sensor mounting bolts and dash sensor, Fig. 35. 4. Reverse procedure to install, noting the following: a. Tighten dash attaching bolts to specifications. b. After completing installation, place ignition switch in On position. SRS indicator lamp should be illuminated for approximately six seconds, then lamp should turn off. If lamp remains illuminated or does not illuminate, a problem in the SRS is indicated. 5. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Safing Sensor, Air Bag > Component Information > Locations Safing Sensor: Locations The Safing Sensor is located within the SRS Unit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Locations > Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Locations > Component Locations > Page 7980 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Locations > Page 7981 Malfunction Lamp / Indicator: Testing and Inspection Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Locations > Page 7982 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Locations > Page 7983 The SRS Indicator Light Doesn't Come On. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module: Locations Right Side Of Driver's Footwell Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 7988 Air Bag Control Module: Service and Repair 1. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. 2. Disconnect battery negative cable, then positive cable. 3. Pull down carpeting from both sides of front console and remove harness protector. 4. Disconnect SRS control unit connector. 5. Remove four SRS control unit mounting bolts, then control unit from vehicle. 6. Reverse procedure to install, noting the following: a. Tighten attaching bolts to specifications. b. After completing installation, place ignition switch in On position. SRS indicator lamp should be illuminated for approximately six seconds, then lamp should turn off. If lamp remains illuminated or does not illuminate, a problem in the SRS is indicated. 7. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Specifications Air Bag(s) Arming and Disarming: Specifications Component .......................................................................................................................................... ....................................................... Torque/Ft. Lbs. Dash Sensor Mounting Bolts .............................. .............................................................................................................................................................. .. 16 Driver Side Air Bag Assembly To Steering Wheel Bolts ................................................................................................................................................. 7.2 Passenger Side Air Bag Mounting Nuts & Bolts .................................................................................. ............................................................................. 7.2 SRS Unit Mounting Bolts ................................. .............................................................................................................................................................. .. 7.2 Steering Wheel To Column Steering Shaft Nut .......................................................................... ....................................................................................... 36 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Specifications > Page 7993 Air Bag(s) Arming and Disarming: Service Precautions 1. On models with 3-P SRS connectors, install red short connectors on air bags prior to disconnecting any part of SRS wiring harness. 2-P SRS connectors automatically short when disconnected. 2. Always use test harnesses. Do not use test probes directly on component connector pins or wires. 3. When connecting any test harnesses, push connectors straight in until secure. Do not bend connector pins. 4. Always keep red short connector on air bag connector when harness is disconnected. 5. Always store air bag assembly with pad surface facing upward. 6. Do not attempt to disassemble air bag assembly. 7. An air bag that has been deployed cannot be repaired or reused. 8. Keep air bag assembly free of oil and grease. 9. Do not expose air bag assembly to temperatures above 212°F. 10. Do not use SRS components from another vehicle. Always install new replacement components. 11. Do not paint air bag assembly to correct cosmetic flaws. It must be replaced. 12. Inspect all components prior to installation. Do not install any that appear to have been improperly handled or stored or that show any signs of damage. 13. When repairing vehicle, system should be disarmed as outlined under Technician Safety Information. 14. When performing service procedures, do not expose sensors or wiring or other SRS components to heat guns, welding or spray guns. 15. SRS wiring should not be spliced, soldered or repaired. 16. Use only special digital multimeter tool No. KS-AHM-32-003, or equivalent, digital multimeter with 0.0 mA or smaller output when switched to lowest ohmmeter range to inspect system. Analog or testers with higher outputs can damage circuits or cause accidental air bag deployment and, if equipped, seat belt pretensioner activation. 17. Do not bump SRS unit whenever ignition is turned On, or has been Off for less than three minutes. Unwanted deployment could result. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Specifications > Page 7994 Air Bag(s) Arming and Disarming: Service and Repair The Supplemental Restraint System (SRS) must be disarmed prior to disconnecting any electrical connectors or servicing any system components or items located near SRS electrical connectors. SRS electrical wiring can be identified by its yellow outer protective coating. To disarm the SRS, proceed as follows: 1. Obtain five-digit radio theft protection code number. 2. Disconnect battery ground cable, then the positive cable. Fig. 1 Driver Air Bag Disarming 3. After disconnecting cables, wait at least three minutes with ignition turned Off before disconnecting any SRS electrical connectors. This will allow air bag system back-up circuit capacitor to discharge. 4. Remove steering wheel access panel and disconnect electrical connector located between air bag and cable reel, Fig. 1 5. Remove glove compartment and access panel. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Specifications > Page 7995 Fig. 4 Passenger Air Bag Disarming 6. Disconnect front passenger air bag 3-P connector from SRS main harness and connect red short connector, Fig. 4. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Specifications > Page 7996 Fig. 12 Fuse Panel/SRS Connector 7. Using thin blade screwdriver, lift SRS to under-instrument panel fuse connector lid, Fig. 12, then press tab down and slide connector out. 8. Reverse procedure to reactivate system, noting following: a. Slide harness electrical connector onto fuse panel connections until it clicks, then close connector lid. b. Ensure all red short connectors have been removed and placed in their holders. c. Prior to connecting battery ground and positive cables, ensure all supplemental restraint system electrical connectors have been properly connected. d. After battery cables have been connected, turn ignition switch to On position. SRS indicator lamp should light for approximately six seconds. If lamp does not light or remains on longer than six seconds, A SYSTEM MALFUNCTION IS INDICATED. Refer to Testing and Inspection / Procedures See: Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview e. Turn radio control to On. When word Code appears on display panel, enter five-digit theft protection code number. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Customer Interest for Seat Belt: > 93033 > Jun > 96 > Seat Belt - Tongue Stopper Button Broken Seat Belt: Customer Interest Seat Belt - Tongue Stopper Button Broken Bulletin No. 93-033 Issue Date JUNE 3, 1996 Model: 1992 and Later [NEW] Applicable To: ALL except PASSPORT [NEW] File Under: BODY Broken Seat Belt Tongue Stopper Button (Supersedes 93-033, dated October 22, 1993) PROBLEM The seat belt tongue stopper button is broken, allowing the tongue to slide down to the floor. CORRECTIVE ACTION Install a new seat belt tongue stopper button listed under PARTS INFORMATION. 1. Slide the seat belt tongue up the seat belt past the tongue stopper button hole. Temporarily secure the seat belt tongue to the belt fabric with masking tape. 2. Insert the male section of the button through the hole in the belt fabric. Align and install the female section of the stopper to the male section. 3. Preset the closed gap on a pair of vise-grip pliers to 4.5 mm. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Customer Interest for Seat Belt: > 93033 > Jun > 96 > Seat Belt - Tongue Stopper Button Broken > Page 8005 4. Place the flat portion of the jaws over the tongue stopper, and squeeze until the vise-grip jaws lock and deform the stopper shaft. PARTS INFORMATION Seat Belt Tongue Stopper: WARRANTY CLAIM INFORMATION Warranty Coverage: Seat belts that fail to function properly during normal use are covered under warranty for the useful life of the car. Warranty Does Not Cover: ^ Malfunction due to abuse, alteration, accidental damage or damage resulting from a collision or misuse. ^ Replacement of a properly functioning seat belt for cosmetic or comfort reasons. Operation number: 854125 Flat rate time: 0.2 hour (one or two sides) Failed part: P/N 04814-SM1-AO2ZA [NEW] H/C 3919289 Defect code: L18 Contention code: A02 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 93033 > Jun > 96 > Seat Belt - Tongue Stopper Button Broken Seat Belt: All Technical Service Bulletins Seat Belt - Tongue Stopper Button Broken Bulletin No. 93-033 Issue Date JUNE 3, 1996 Model: 1992 and Later [NEW] Applicable To: ALL except PASSPORT [NEW] File Under: BODY Broken Seat Belt Tongue Stopper Button (Supersedes 93-033, dated October 22, 1993) PROBLEM The seat belt tongue stopper button is broken, allowing the tongue to slide down to the floor. CORRECTIVE ACTION Install a new seat belt tongue stopper button listed under PARTS INFORMATION. 1. Slide the seat belt tongue up the seat belt past the tongue stopper button hole. Temporarily secure the seat belt tongue to the belt fabric with masking tape. 2. Insert the male section of the button through the hole in the belt fabric. Align and install the female section of the stopper to the male section. 3. Preset the closed gap on a pair of vise-grip pliers to 4.5 mm. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 93033 > Jun > 96 > Seat Belt - Tongue Stopper Button Broken > Page 8011 4. Place the flat portion of the jaws over the tongue stopper, and squeeze until the vise-grip jaws lock and deform the stopper shaft. PARTS INFORMATION Seat Belt Tongue Stopper: WARRANTY CLAIM INFORMATION Warranty Coverage: Seat belts that fail to function properly during normal use are covered under warranty for the useful life of the car. Warranty Does Not Cover: ^ Malfunction due to abuse, alteration, accidental damage or damage resulting from a collision or misuse. ^ Replacement of a properly functioning seat belt for cosmetic or comfort reasons. Operation number: 854125 Flat rate time: 0.2 hour (one or two sides) Failed part: P/N 04814-SM1-AO2ZA [NEW] H/C 3919289 Defect code: L18 Contention code: A02 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions Seat Belt Reminder Lamp: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8016 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8017 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8018 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8019 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8020 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8021 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8022 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8023 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8024 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8025 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8026 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8027 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8028 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8029 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8030 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8031 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8032 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8033 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8034 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8035 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8036 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8037 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8038 Seat Belt Reminder Lamp: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8039 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8040 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8041 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8042 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8043 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8044 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8045 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8046 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8047 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8048 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8049 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8050 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8051 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8052 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8053 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8054 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8055 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8056 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8057 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8058 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8059 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8060 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8061 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8062 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8063 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8064 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8065 Seat Belt And Ignition Key Reminders Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Page 8066 Seat Belt Reminder Lamp: Description and Operation With the ignition switch in ON (II) or START (III), battery voltage is applied to the seat belt reminder light. When the seat belt is not buckled the seat belt reminder/key-ON beeper circuit in the integrated control unit senses ground through the closed seat belt switch. The seat belt reminder light flashes ON and OFF for five seconds. The reminder light and beeper will go OFF when the seat belt is buckled or the timer circuit deactivates them. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair Impact Sensor: Service and Repair 1. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. 2. Remove footrest and left door sill molding, then pull back carpet. Fig. 35 Dash Sensor Mounting 3. Remove dash sensor protector, then sensor mounting bolts and dash sensor, Fig. 35. 4. Reverse procedure to install, noting the following: a. Tighten dash attaching bolts to specifications. b. After completing installation, place ignition switch in On position. SRS indicator lamp should be illuminated for approximately six seconds, then lamp should turn off. If lamp remains illuminated or does not illuminate, a problem in the SRS is indicated. 5. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Safing Sensor, Air Bag > Component Information > Locations Safing Sensor: Locations The Safing Sensor is located within the SRS Unit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information Technical Service Bulletin # 98-011 Date: 040220 Keyless Entry - Remote Transmitter Information 98-011 February 20, 2004 Applies To: ALL Keyless Remote Transmitter Information (Supersedes 98-011, dated February 6, 2003) Updated information is shown by asterisks and a black bar. This service bulletin gives you information about keyless remote transmitters for most Honda vehicles. Each procedure describes transmitter programming (if applicable), transmitter ordering, and transmitter batteries. A remote transmitter quick reference guide is shown below. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8081 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8082 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8083 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8084 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8085 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8086 Remote Transmitter Quick Reference Guide 90-93 Accord, 92-93 Civic & Prelude, 93 Del SOL 1990-93 Accord (2-door and 4-door) with dealer-installed security system 1992-93 Civic with dealer-installed security system 1993 del Sol with dealer-installed security system 1992-93 Prelude with dealer-installed security system Programming the Transmitter NOTE: Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8087 This system uses ROM chips that match the transmitter to the security system control unit. When replacing a lost or stolen transmitter, you need to use the three ROM chips (provided with the new transmitter) to match the old transmitter with the new transmitter and the control unit. 1. Remove the rear cover from the old transmitter and the new one. 2. Remove the ROM chip from the old transmitter by sliding its socket holder toward the ROM chip. 3. Insert a new ROM chip into the socket holder, then slide the socket holder toward the socket to lock the chip in place. 4. Repeat step 3 to install a ROM chip into the new transmitter. 5. Reinstall the rear covers on the transmitters. 6. Remove the security system control unit from under the driver's seat. 7. Open the access cover on the control unit, and replace the ROM chip. (Use the same procedure as in steps 2 and 3.) 8. Press the reset button next to the ROM chip. 9. Close the access cover, and reinstall the control unit. If you are replacing a damaged transmitter, don't replace the ROM chips in the transmitters and the control unit; just remove the chip from the old transmitter and install it in the new one. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. If your customer wants to add a third transmitter to the system, you need to order a four ROM chip set directly from Alpine Electronics of America. The Alpine part number for the four ROM chip set is 5319. This ROM chip set does not come with a transmitter. Order the additional transmitter from American Honda. If you have questions about how to order a four ROM chip set, call Alpine's parts department at (800) 421-2284, extension 8885. Batteries for the Transmitter Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8088 The battery number is CR2025. Each transmitter uses one battery. 94-95 Accord, Civic, Del SOL, Prelude & 95 Odyssey 1994-95 Accord with dealer-installed security system 1994-95 Civic with dealer-installed security system 1994-95 del Sol with dealer-installed security system 1994-95 Prelude with dealer-installed security system 1995 Odyssey with dealer-installed security system Programming the Transmitter NOTES: ^ The system uses a stacking-type memory that accepts up to four transmitters. If you program a fifth transmitter, the system's memory for the first transmitter is pushed out, and it will no longer work. ^ To clear a lost or stolen transmitter from the system's memory, program a transmitter four times. This will remove the missing transmitter from memory, since only four transmitter codes can be accepted. ^ Another way to clear a lost or stolen transmitter is to erase all transmitter codes, and then reprogram them. To do this, refer to the security system owner's manual. 1. Turn the ignition switch to ON (II). 2. Press and hold the Valet-Disarm button on the dashboard lower cover. (Continue to hold the button during this procedure, or programming will be cancelled.) The LED on the upper steering column cover flashes when the system is in programming mode. 3. Press the top button on the transmitter. Check that the parking lights flash to confirm that the transmitter's code was accepted. 4. Press the top button on each of the remaining transmitters. Check that the parking lights flash after each transmitter code is accepted. 5. Release the Valet-Disarm button to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 96-98 Civic EX & Except EX, Civic 1996-98 Civic EX with factory-installed keyless entry system 1996-98 Civic (except EX) with dealer-installed keyless entry system 1996-98 Civic with dealer-installed security system Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8089 Programming the Transmitter NOTES: ^ The system accepts up to four transmitters. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all the transmitters once you're in the programming mode. 1. Turn the ignition switch to ON (II). 2. Press and hold the Valet-Disarm button on the radio (between the AM/FM and CD/TAPE buttons) to enter the programming mode. (Continue to hold the button during this procedure, or programming will be cancelled.) Check that the power door locks cycle to confirm that you're in the programming mode. 3. Within 5 seconds, press the "Lock" or "Unlock" button on the transmitter. Check that the power door locks cycle to confirm that the code was accepted. 4. Within 10 seconds, press the "Lock" or "Unlock" button on each of the remaining transmitters. 5. After all the transmitters have been programmed, release the Valet-Disarm button to exit programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 99-04 Civic, 03-04 Accord, Element, Pilot 1999-00 Civic Value Package with factory-installed keyless entry system 1999-04 Civic EX with factory-installed keyless entry system or dealer-installed security system *1999-03 Civic (except EX) with dealer-installed keyless entry system or security system 2002-04 Civic Si with factory-installed keyless entry system or dealer-installed security system 2003-04 Civic Hybrid with factory-installed keyless entry system or dealer-installed security system 2004 Civic (except LX & EX) with dealer-installed keyless entry system or security system 2004 Civic LX with factory-installed keyless entry system or dealer-installed security system Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8090 2003-04 Accord DX with dealer-installed security system 2003-04 Element with dealer-installed keyless entry system or security system 2004 Element EX with factory-installed keyless entry system or dealer-installed security system 2003-04 Pilot EX models with factory-installed security system* Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 91-93 Accord 5-D00R EX Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8091 1991-93 Accord 5-door EX with factory-installed keyless entry or dealer-installed security system Programming the Transmitter The transmitter is not programmable. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. To order a transmitter, you need the vehicle's VIN, the code number from the power door lock control unit, and the ignition key code number. The power door lock code number is a five-digit number etched into the plastic case of the control unit (mounted under the driver's seat). The ignition key code number is a four-digit number stamped on the metal shank of all five original keys delivered with the car. Replacement transmitters are manufactured to match the code of the keyless entry system. The new ignition key is cut to match the vehicle's ignition switch, front door locks, tailgate lock, and glove compartment lock. To order this transmitter, use the controlled parts ordering screen on the iN system. The transmitters are manufactured in Japan; delivery takes 4 to 6 weeks. Batteries for the Transmitter The battery is not replaceable. 91-93 Accord 5-Door LX 1991-93 Accord 5-door LX with dealer-installed security system Programming the Transmitter This transmitter is not programmable. Ordering a Transmitter Transmitters can be ordered directly from Kenwood USA only by authorized Honda dealers. Send a completed order form (copy it from the Accessory Replacement Parts section of the Dealer Parts Price List) along with a dealer check for $30.00 (payable to Kenwood U.S.A. Corp.) to this address: Kenwood Service Corp. P.O. Box 22745 Long Beach, CA 90501-5745 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8092 On the order form, you must include the serial number of the keyless control unit or the number from one of the original transmitters. If you need a transmitter shipped overnight, fill out the order form, then call Kenwood at (500) 552-4690, or fax them at (310) 595-1029 (weekdays from 5:30A.M. thru 4:00 P.M. Pacific time). You will need to give the information on the order form to the Kenwood representative. The transmitter will be sent to your dealership COD. Additional shipping and handling charges will be applied to the order. Batteries for the Transmitter The battery number is CR1220. Each transmitter uses two batteries. 94-97 Accord 5-Door EX, 95-98 Odyssey EX 1994-97 Accord 5-door EX with factory-installed keyless entry system 1995-98 Odyssey EX with factory-installed keyless entry system Programming the Transmitter NOTE: ^ The system accepts up to two transmitters. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. 1. Open the driver's door. 2. Push the driver's power door lock switch to the unlock position and hold it. (Continue to hold the switch during this procedure.) 3. Insert the key into the ignition switch, then remove it. Repeat this four more times (five times total) within 10 seconds. (You must complete steps 3 and 4 within 10 seconds or the system will exit the programming mode.) 4. Insert the key into the ignition switch. After you insert the key, make sure the power door locks cycle to confirm that the system is in the programming mode. 5. Press the "LOCK" or "UNLOCK" button on the transmitter. All the power door locks (except the driver's door) should cycle to confirm that the system accepted the transmitter's code. 6. To program a second transmitter, press its "LOCK" or "UNLOCK" button within 10 seconds of programming the first transmitter. 7. Release the master power door lock switch to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2016. Each transmitter uses two batteries. 96-04 Accord, CRV, DelSOL, Ody., Prelude, S2000, Insight, Pilot 1996-02 Accord with dealer-installed security system 1998-02 Accord DX & LX with dealer-installed keyless entry system Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8093 1997-01 CR-V with dealer-installed security system 1996-97 del Sol with dealer-installed security system 1996-98 Odyssey with dealer-installed security system *1999-04 Odyssey LX with dealer-installed keyless entry system or security system* 1996-01 Prelude with dealer-installed security system *2000-04 S2000 with dealer-installed security system 2000-04 Insight with dealer-installed security system 2003-04 Pilot LX with dealer-installed keyless entry system or security system* Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8094 1997 Accord SE With Factory-Installed Security System 1997 Accord SE with factory-installed security system Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 5. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 98-02 Accord EX & 00-02 Accord SE 1998-02 Accord EX with factory-installed security system 2000 and 2002 Accord SE with factory-installed security system Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8095 (Not interchangeable with CR-V and S2000 remote transmitter) Transmitter Identification The transmitter for the 1995-99 Accord and the 2000-02 Accord look identical, but they are not interchangeable. The 1995-99 transmitter works the doors of a 2000-02 Accord, but it does not open the trunk. If you are not sure which transmitter you have, press and hold the trunk release button while looking at the LED. The LED on the 1995-99 transmitter comes on in about 1.1 seconds. The LED on the 2000-02 transmitter comes on in about 0.5 second. Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 03-04 Accord LX and EX 2003-04 Accord LX and EX with factory-installed keyless entry system Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8096 Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR1616. Each transmitter uses one battery. 97-04 CR-V & 00-04 S2000 *1997-04 CR-V LX with dealer-installed keyless entry system 1998-04 CR-V EX with factory-installed keyless entry system 2000-01 CR-V SE with factory-installed keyless entry system 2000-04 S2000 with factory-installed keyless entry system 2002-04 CR-V with dealer-installed security system* Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8097 Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete each step within 4 seconds of the previous step to keep the system from exiting the programming mode. Program the transmitters within 10 seconds. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 99-04 Odyssey EX 1999-00 Odyssey EX with factory-installed keyless entry system or dealer-installed security system *2001-04 Odyssey EX models with factory- installed security system* *Transmitter Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8098 The 1999-00 transmitter is not interchangeable with the 2001-04 transmitter. To tell them apart, look at the FCC ID on the back. 1999-00 - FCC ID: E4EG8DN 2001-04 - FCC ID: OUCG8D-440H-A* Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 99-01 Prelude With Factory-Installed Keyless Entry System 1999-01 Prelude with factory-installed keyless entry system Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8099 Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 88-91 Prelude With Dealer-Installed Security System 1988-91 Prelude with dealer-installed security system Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8100 Programming the Transmitter This transmitter is not programmable. Ordering a Transmitter This transmitter is no longer available. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses two batteries. 97-99 EV Plus With Factory-Installed Security System 1997-99 EV Plus with factory-installed security system Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 5. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only through Tech Line. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 00-04 Insight With Factory-Installed Keyless Entry System 2000-04 Insight with factory-installed keyless entry system Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8101 Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 94-95 Passport (Except 1995-1/2) 1994-95 Passport (except 19951A) with dealer-installed security system NOTES: ^ The system uses a stacking-type memory that accepts up to four transmitters. If you program a fifth transmitter, the memory for the first transmitter is pushed out, and it will no longer work. ^ To clear a lost or stolen transmitter from the system's memory, program a transmitter four times. This will remove the missing transmitter from memory, since only four transmitters can be accepted. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8102 Programming the Transmitter 1. Locate the security system control unit under the driver's seat. 2. Rub your finger over the label on the top of the control unit until you find the depression. Once you find it, push your finger through the label to expose the hole underneath. Inside the hole is a square, yellow button; this is the programming button. 3. Turn the ignition switch to ON, then turn it to LOCK. 4. Press and hold the programming button. Check that the security siren emits four separate chirps followed by a five-chirp burst. This confirms that the system is in programming mode. The siren then emits prompting chirps at 3-second intervals. 5. Release the programming button. 6. After a prompting chirp, press the "LOCK" button on the transmitter. Verify that the siren emits a confirmation chirp to confirm that the transmitter's code was accepted by the control unit. If you wait more than 30 seconds after the prompting chirp before programming a transmitter, or wait more than 30 seconds between programming transmitters, the siren emits three chirps and the system exits the programming mode. 7. To program additional transmitters, wait for another prompting chirp, then press the "LOCK" button. (You can program up to four transmitters per vehicle.) 8. To exit the programming mode, turn the ignition switch to ON, then turn it to LOCK. 9. Test all the transmitters. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is 23-144 (Radio Shack), A-23 (Eveready), or MS-21/MN-21 (Duracell). Each transmitter uses one battery. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8103 96-97 Passport With Dealer-Installed Security System 1996-97 Passport with dealer-installed security system NOTES: ^ The system uses a stacking-type memory that accepts up to two transmitters. If you program a third transmitter, the memory for the first transmitter is pushed out, and it will no longer work. ^ To clear a lost or stolen transmitter from the system's memory, program a transmitter two times. This will remove the missing transmitter from memory, since only two transmitter codes can be accepted. ^ Another way to clear a lost or stolen transmitter is to erase all transmitter codes and then reprogram them. To do this, refer to the security system owner's manual. Programming the Transmitter 1. Move the driver's seat forward. Locate the security system control unit mounted on the floor underneath the seat. 2. Turn the ignition switch to ON. 3. Use a pen or pencil to press and hold the green programming button on the side of the control unit. When the security system LED on the instrument panel comes on, release the programming button. (Steps 3 and 4 must be done within 5 seconds of each other.) 4. Press and release the top button on the transmitter. Verify that the LED goes out, the siren chirps once, and the front sidemarker lights flash to confirm that the transmitter's code was accepted by the control unit. 5. Turn the ignition switch to LOCK, then to ON. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8104 6. Press and hold the green programming button on the side of the control unit until the LED on the instrument panel begins to flash, then release the button. (Steps 6 and 7 must be done within 5 seconds of each other.) 7. Press and release the bottom button on the transmitter. Verify that the LED goes out, the siren chirps twice, and the front sidemarker lights flash twice to confirm that the transmitter's code was accepted by the control unit. 8. Turn the ignition switch to LOCK. Test the transmitter you just programmed. If it doesn't work repeat steps 2 thru 7. 9. If you have another transmitter to program, repeat steps 2 thru 7. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 98-02 Passport With Factory-Installed Security System 1998-02 Passport with factory-installed security system Programming the Transmitter To program the transmitters, use one of these two procedures: ^ Procedure One cancels all learned transmitter codes and adds one new transmitter. None of the previously programmed transmitters will work. Use this programming procedure only if all transmitters were lost or stolen, or if a new control unit has been installed. ^ Procedure Two adds additional transmitters without cancelling any of the previously learned codes. The system will accept up to four transmitters. Procedure One (cancels all codes, adds one new transmitter) 1. Open the driver's door. 2. Turn the ignition switch to the ACC position and then to the LOCK position three times. (This step must be completed within 10 seconds, or the system will not enter the programming mode.) 3. Within 10 seconds, close and open the door two times. 4. Turn the ignition switch to the ACC position and then to the LOCK position five times. Close and open the door. (Complete this process within 10 seconds.) Verify that the power door locks cycle once to confirm that the system is in programming mode. 5. Within 20 seconds, press the "LOCK" button on the transmitter you are programming. Verify that the door locks cycle once. 6. Within 20 seconds, press the "UNLOCK" button on the transmitter. Verify that the door locks cycle once to confirm that the system has accepted the transmitter's code. Procedure Two (adds transmitters) 1. Open the driver's door. 2. Turn the ignition switch to the ACC position and then to the LOCK position three times. (This step must be completed within 10 seconds, or the Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8105 system will not enter the programming mode.) 3. Within 10 seconds, close and open the door two times. 4. Turn the ignition switch to the ACC position and then to the LOCK position three times. Close and open the door. (Complete this process within 10 seconds.) Verify that the power door locks cycle once to confirm that the system is in programming mode. 5. Within 20 seconds, press the "LOCK" button on the transmitter you are programming. Verify that the door locks cycle once. 6. Within 20 seconds, press the "UNLOCK" button on the transmitter. Verify that the door locks cycle once to confirm that the system has accepted the transmitter's code. Turning the Audible Chirp On/Off (1998-99 only) NOTE: On '00-02 Passports, the audible chirp sounds only when you push the LOCK button on the transmitter a second time. 1. Open the driver's door, then insert the key in the driver's door lock. 2. Turn the key to the "LOCK" position, then to the "UNLOCK" position. Repeat this two more times. (Complete this procedure within 10 seconds.) 3. Within 10 seconds, close and open the door two times. 4. Within 10 seconds, turn the key to the "LOCK" position, and then to the "UNLOCK" position, three times. Close and open the door once. Verify that the power door locks cycle once to confirm that the chirp has been turned on/off. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2016. Each transmitter uses two batteries. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8106 Technical Service Bulletin # 96-046 Date: 961021 Keyless Entry - Transmitter Programming Information Bulletin No. 96-046 Issue Date OCT 21, 1996 Model ALL Applicable To Refer to the list below File Under ACCESSORIES Keyless Remote Transmitter Information This Service Bulletin gives you information about keyless remote transmitters for most Honda vehicles. Each procedure describes transmitter programming (if applicable), transmitter ordering*, and transmitter batteries. A transmitter quick reference guide is included. Use this index to find the information for the vehicle you are working on. Vehicle: Procedure Number: Civic 1992-93 2 1994-95 5 1996-97 8 del Sol 1993 2 1994-95 5 1996-97 7 Accord 1990-93 (except Wagon) 2 1991-93 EX Wagon 3 1991-93 LX Wagon 4 1994-95 (with optional security system) 5 1994-97 EX Wagon 6 1996-97 (with optional security system) 7 Prelude 1988-91 1 1992-93 (with optional security system) 2 1994-95 (with optional security system) 5 1996-97 (with optional security system) 7 Odyssey 1995 (with optional security system) 5 1995-97 EX 6 1996-97 (with optional security system) 7 Passport 1994-95 (with optional security system, not applicable to 1995.5 model) 9 1996-97 (with optional security system) 10 *Transmitter prices are subject to change without notice. PARTS INFORMATION Transmitter ordering information and battery part numbers are in each transmitter section. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8107 WARRANTY CLAIM INFORMATION None. This Service Bulletin is for information only. TRANSMITTER QUICK REFERENCE GUIDE Procedure 1 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8108 Programming the Transmitter This transmitter is not programmable. Ordering the Transmitter Transmitters can be ordered directly from Alpine of America by authorized Honda Dealers only. Send a completed order form (found in Parts Information Bulletin A91 -0031) along with a dealer check for $59.00 (payable to Alpine of America), to this address: Honda/Alpine V.S.S. P.O. Box 2859 Torrance, CA 90509 Batteries for the Transmitter The battery number is CR2025. Each transmitter uses two batteries. Procedure 2 Programming the Transmitter NOTE: This system uses ROM chips that match the transmitter to the security system control unit. When replacing a lost or stolen transmitter, you need to use the three ROM chips (provided with the new transmitter) to match the old transmitter with the new transmitter and the control unit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8109 1. Remove the rear cover from the old transmitter and the new one. 2. Remove the ROM chip from the old transmitter by sliding its socket holder toward the ROM chip. 3. Insert a new ROM chip into the socket holder, then slide the socket holder toward the socket to lock the chip into place. 4. Repeat step 3 to install a ROM chip into the new transmitter. 5. Reinstall the rear covers on the transmitters. 6. Remove the security system control unit from under the driver's seat. 7. Open the access cover on the control unit, and replace the ROM chip. (Use the same procedure as in steps 2 and 3.) 8. Close the access cover, and reinstall the control unit. If you are replacing a damaged transmitter, don't replace the ROM chips in the transmitters and the control unit; just remove the chip from the old transmitter, and install it in the new one. Ordering the Transmitter Transmitters can be ordered only by authorized Honda Dealers. Order them from American Honda using normal parts ordering procedures. If your customer wants to add a third transmitter to the system, you need to order a four ROM chip set directly from Alpine Electronics of America. The Alpine part number for the four ROM chip set is 8319. For each set ordered, send a dealer check for $24.00 (payable to Alpine of America), to this address: Alpine Electronics of America 19145 Gramercy Place Torrance, CA 90501 Attention: Al Sula (Parts) Alpine's ROM chip set does not come with a transmitter. Additional transmitters can be ordered from American Honda using normal parts ordering procedures. If you have questions on how to order the four ROM chip set, call Alpine's Parts Department at (800) 421-2284, extension 8885. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8110 Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. Procedure 3 Programming the Transmitter This transmitter is not programmable. Ordering the Transmitter Transmitters can be ordered only by authorized Honda Dealers. To order a transmitter, you need the vehicle's VIN, the code number from the power door lock control unit, and the ignition key code number. The power door lock code number is a five-digit number etched into the plastic case of the control unit (mounted under the driver's seat). The ignition key code number is a four-digit number stamped on the metal shank of all five original keys delivered with the car. Replacement transmitters are manufactured to match the code of the keyless entry system. The new ignition key is cut to match the vehicle's ignition switch, front door locks, tailgate lock, and glove compartment lock. To order this transmitter, use the controlled parts ordering screen on the HONDANET 2000 system. The transmitters are manufactured in Japan; delivery takes 4 to 6 weeks. Batteries for the Transmitter The battery is not replaceable. Procedure 4 Programming the Transmitter Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8111 This transmitter is not programmable. Ordering the Transmitter Transmitters can be ordered directly from Kenwood USA by authorized Honda Dealers only. Send a completed order form,* (copy it from the Accessory Replacement Parts section of the Dealer Parts Price List) along with a dealer check for $30.00 (payable to Kenwood U.S.A. Corp.), to this address: Kenwood Service Corp. P.O. Box 22745 Long Beach, CA 90801-5745 If you need a transmitter shipped overnight, fill out the order form, then call Kenwood at (800)852-4690, or Fax them at (310) 898-1029 (weekdays, from 8:30 A.M. thru 4:00 PM., PST). You will need to give the information on the order form to the Kenwood representative. The transmitter will be sent to your Dealership C.O.D. Additional shipping and handling charges will be applied to the order. Batteries for the Transmitter The battery number is CR1220. Each transmitter uses two batteries. *On the order form, you must include the serial number of the keyless control unit or the number from one of the original transmitters. Procedure 5 Programming the Transmitter NOTES: ^ The system uses a stacking-type memory that accepts up to four transmitters. If you program a fifth transmitter, the system's memory for the first transmitter is pushed out, and it will no longer work. ^ To clear a lost or stolen transmitter from the system's memory, program a transmitter four times. This will remove the missing transmitter from memory, since only four transmitter codes can be accepted. ^ Another way to clear a lost or stolen transmitter is to erase all transmitter codes and then reprogram them. To do this, refer to the security system owner's manual. 1. Turn the ignition switch ON (II). 2. Press and hold the Valet-Disarm button on the dashboard lower cover. (Continue to hold the button during the procedure, or programming will be cancelled.) The LED on the upper steering wheel cover flashes when the system is in the programming mode. 3. Press the top button on the transmitter. The parking lights flash to confirm that the transmitter's code was accepted. 4. Press the top button on each of the remaining transmitters. The parking lights flash after each transmitter code is accepted. 5. Release the Valet-Disarm button to exit the programming mode. Ordering the Transmitter Transmitters can be ordered only by authorized Honda Dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8112 The battery number is CR2025. Each transmitter uses one battery. Procedure 6 Programming the Transmitter NOTE: Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all the transmitters once you are in the programming mode. 1. Open the driver's door. 2. Press and hold the driver's door master power door lock switch up in the unlock position. (Continue to hold the switch during this procedure.) 3. Insert the key in the ignition switch and remove it. Repeat this four more times within 10 seconds, then leave the key in the switch. Check that the power door locks cycle to confirm that the system is in the programming mode. (This step must be completed within 10 seconds, or the system will exit the programming mode.) 4. Press the "LOCK" or "UNLOCK" button on the transmitter. Check that all power door locks (except the driver's) cycle to confirm that the transmitter's code was accepted by the system. 5. To program a second transmitter, press its "LOCK" or UNLOCK" button within 10 seconds of programming the first transmitter. (You can program two transmitters per vehicle.) 6. Release the master power door lock switch to exit the programming mode. Ordering the Transmitter Transmitters can be ordered only by authorized Honda Dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2016. Each transmitter uses two batteries. Procedure 7 Programming the Transmitter Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8113 NOTES: ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all the transmitters once you're in the programming mode. ^ To keep the system from exiting the programming mode, complete each step within 5 seconds of the previous step, and program the transmitters within 10 seconds of each other. 1. Turn the ignition switch ON (II). 2. Press the "LOCK" or "UNLOCK" button on one of the transmitters. (A non-programmed transmitter can be used for this step.) 3. Turn the ignition switch OFF (0). 4. Repeat steps 1, 2, and 3 two more times with the transmitter used in step 2. 5. Turn the ignition switch ON (II). 6. Press the "LOCK" or "UNLOCK" button on the same transmitter. Check that the power door locks cycle to confirm that you're in the programming mode. 7. Press the "LOCK" or "UNLOCK" button on each transmitter. (You can program up to four transmitters per vehicle) Check that the power door locks cycle after you push each transmitter button, confirming that the system has accepted the transmitter's code. Ordering the Transmitter Transmitters can be ordered only by authorized Honda Dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. Procedure 8 Programming the Transmitter NOTES: ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all the transmitters once you're in the programming mode. ^ To keep the system from exiting the programming mode, complete each step within 5 seconds of the previous step, and program the transmitters within 10 seconds of each other. 1. Turn the ignition switch ON (II). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8114 2. Press and hold the Valet-Disarm button on the radio (between the AM/FM button and the CD/TAPE button) to enter the programming mode. (Continue to hold the button during the procedure, or programming will be cancelled.) Check that the power door locks cycle to confirm that you're in the programming mode. 3. Press the "LOCK" or "UNLOCK" button on the transmitter. Check that the power door locks cycle to confirm that the code was accepted. 4. Press the "LOCK" or "UNLOCK" button on all other transmitters. (You can program up to four transmitters per vehicle.) 5. After all the transmitters have been programmed, release the Valet-Disarm button to exit the programming mode. Ordering the Transmitter Transmitters can be ordered only by authorized Honda Dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. Procedure 9 NOTES: ^ The system uses a stacking-type memory that accepts up to four transmitters. If you program a fifth transmitter, the memory for the first transmitter is pushed out, and it will no longer work. ^ To clear a lost or stolen transmitter from the system's memory, program a transmitter four times. This will remove the missing transmitter from memory, since only four transmitter codes can be accepted. Programming the Transmitter Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8115 1. Locate the security system control unit mounted under the driver's seat. 2. Rub your finger over the label on the top of the control unit until you find the depression. Once you find it, push your finger through the label to expose the hole underneath. Inside the hole is a square, yellow button; this is the programming button. 3. Turn the ignition switch on, then turn it off. 4. Press and hold the programming button. Check that the security siren emits four separate chirps followed by a five-chirp burst to confirm that you're in the programming mode. The siren then emits prompting chirps at three-second intervals. 5. Release the programming button. 6. After a prompting chirp, press the "LOCK" button on the transmitter. Check that the siren emits a confirmation chirp to let you know that the transmitter's code was accepted by the control unit. If you wait more than 30 seconds after the prompting chirp before programming a transmitter or between programming transmitters, the siren emits three chirps, and the system exits the programming mode. 7. To program additional transmitters, wait for another prompting chirp, then press the "LOCK" button. (You can program up to four transmitters per vehicle.) 8. To exit the programming mode, turn the ignition switch on, then turn it off. 9. Push all the function buttons on each transmitter to make sure they work correctly. Ordering the Transmitter Transmitters can be ordered only by authorized Honda Dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is 23-144 (Radio Shack), A-23 (Eveready), or MS-21/MN-21 (Duracell). Each transmitter uses one battery. Procedure 10 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8116 Programming the Transmitter NOTES: ^ The system uses a stacking-type memory that accepts up to four transmitters. If you program a fifth transmitter, the memory for the first transmitter is pushed out, and it will no longer work. ^ To clear a lost or stolen transmitter from the system's memory, program a transmitter four times, This will remove the missing transmitter from memory, since only four transmitter codes can be accepted. ^ Another way to clear a lost or stolen transmitter is to erase all transmitter codes and then reprogram them. To do this, refer to the security system owner's manual. 1. Move the driver's seat forward, and locate the security system control unit mounted on the floor, underneath the seat. 2. Turn the ignition switch on. 3. Press and hold the green programming button on the side of the control unit with a pen or pencil. When the security system LED on the instrument panel comes on, release the programming button. (Steps 3 and 4 must be done within 5 seconds of each other.) 4. Press and release the top button on the transmitter. Check that the LED goes out, the siren chirps once, and the front marker lights flash to confirm that the transmitter's code was accepted by the control unit. 5. If you have other transmitters to program, repeat steps 3 and 4. 6. Turn the ignition switch off to exit the programming mode. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8117 Ordering the Transmitter Transmitters can be ordered only by authorized Honda Dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. One battery per transmitter is needed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Technical Service Bulletins > Audio System - CD/DVD Precautions DVD Player: Technical Service Bulletins Audio System - CD/DVD Precautions Adhesive Labels or Protective Disc Covers on CDs or DVDs: A Big Taboo NOTE: This article applies to all Honda models with a factory- or dealer-installed CD/DVD player or changer. We can't emphasize this enough: Never put adhesive labels or protective disc covers on recordable CDs or DVDs to be used in automotive CD/DVD players or changers. Here's why: ^ Recordable CDs and DVDs are actually thicker than their pre-recorded brethern. Automotive players and changers use rollers to draw the disc into the unit. The added thickness of an adhesive label or a protective disc cover can cause the disc to jam when it's loaded into or ejected from the unit. ^ CD/DVD players or changers are exposed to high temperatures inside the vehicle. High temperature can cause the label adhesive to soften. This can cause the label to curl on the edges and even form bubbles. Curled edges can catch on the rollers and bubbles add thickness to the disc. Either one can cause the disc to jam. To cut down on customer-caused damage, all '05 and later 0/Ms include this notice: Do not use CDs with adhesive labels. The label can curl up and cause the CD to jam in the unit. Anytime a service customer comes in with a loading or ejecting problem for a CD/DVD player or changer, ask if he or she used any discs with adhesive labels or protective disc covers. If the answer is yes, contact your DPSM for possible goodwill assistance. If the answer is no, then replace the audio unit under normal warranty. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Technical Service Bulletins > Customer Interest: > 00-015 > Mar > 00 > Audio Unit with CD Player/Changer - Error Codes Compact Disc Player (CD): Customer Interest Audio Unit with CD Player/Changer - Error Codes 00-015 March 14, 2000 Applies To: All with CD Player/Changer Audio Unit Error Codes (Replaces 91-007, dated October 6, 1997) *If the audio unit displays an error code, use the troubleshooting tables in this service bulletin to troubleshoot the problem. Refer to service bulletin 98-019 for CD Player/Changer exchange information.* Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Technical Service Bulletins > Customer Interest: > 00-015 > Mar > 00 > Audio Unit with CD Player/Changer - Error Codes > Page 8132 CD Changer Troubleshooting (All except Passport) CD Player Troubleshooting (All except Passport) Radio Troubleshooting (All except Passport) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Technical Service Bulletins > Customer Interest: > 00-015 > Mar > 00 > Audio Unit with CD Player/Changer - Error Codes > Page 8133 CD Player/Changer Troubleshooting (Passport only) Manually Removing a Jammed Magazine (All except Passport) One-piece door model: 1. Remove the changer from the vehicle. 2. Remove the rear cover plate from the changer, and look for a jammed disc. 3. If a disc is jammed between the player and the magazine, turn the loading gear until the disc returns to the player mechanism. Do not attempt to reload the disc back into the magazine. 4. After the disc is loaded into the player mechanism, turn the changer so that the front is facing you. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Technical Service Bulletins > Customer Interest: > 00-015 > Mar > 00 > Audio Unit with CD Player/Changer - Error Codes > Page 8134 5. Insert a thin stainless steel ruler or a "Slim Jim" under the magazine, about 1-1/2" from the right side of the opening. 6. Push the ruler in until it presses against the eject lever at the back of the unit. 7. Slowly remove the ruler and magazine at the same time. Two-piece door model: 1. Remove the changer from the vehicle. 2. Remove the top cover plate from the changer, and look for a jammed tray. 3. If a tray is stuck in the player, reinstall the cover and replace the changer. If all the trays are in the magazine, insert a thin stainless steel ruler or a "Slim Jim" under the magazine, about 1/2" from the right side of the opening. 4. Push the ruler in until it presses against the eject lever at the back of the unit. 5. Slowly remove the ruler and magazine at the same time. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Technical Service Bulletins > Customer Interest: > 00-015 > Mar > 00 > Audio Unit with CD Player/Changer - Error Codes > Page 8135 Manually Removing a Jammed Magazine (Passport only) One-piece door model: 1. Open the changer door. 2. Check to see if all the trays are in the magazine. ^ If a tray is stuck in the changer, replace the changer. ^ If all the trays are in the magazine, place the changer in a horizontal position, and insert a thin stainless steel ruler or a "Slim Jim" under the magazine, about 1/2" from the right side of the opening. 3. Push the ruler in until it presses against the eject lever at the back of the unit. 4. Slowly remove the ruler and magazine at the same time. Two-piece door model: 1. Remove the changer from the vehicle. 2. Remove the top cover plate from the changer, and inspect for a jammed tray. ^ If a tray is stuck in the changer, replace the changer. ^ If all the trays are in the magazine, place the changer in a horizontal position, and insert a thin stainless steel ruler or a "Slim Jim" under the magazine, about 1/2" from the right side of the opening. 3. Push the ruler in until it presses against the eject lever at the back of the unit. 4. Slowly remove the ruler and magazine at the same time. Handling and Inspecting Compact Discs Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Technical Service Bulletins > Customer Interest: > 00-015 > Mar > 00 > Audio Unit with CD Player/Changer - Error Codes > Page 8136 ^ Handle a CD by its edges; never touch the flat surfaces. Contamination from fingerprints, liquids, felt-tip pens, and labels can cause the CD to not play properly, or possibly jam in the drive. ^ When cleaning a disc, use a clean soft cloth. Wipe across the disc from the center to the outside. Do not wipe the disc in a circular motion. ^ A new CD may be rough on the inner and outer edges. The small plastic pieces causing this roughness can flake off and fall on the recording surface of the disc, causing skipping or other problems. Remove these pieces by rubbing the inner and outer edges with the side of a pencil or pen. ^ Various accessories are available to protect CDs and improve the sound quality of CDs. These accessories increase the thickness or diameter of the discs, and should not be used in CD changers. Disclaimer Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compact Disc Player (CD): > SN051000-07 > Oct > 05 > Audio System - CD/DVD Precautions Compact Disc Player (CD): All Technical Service Bulletins Audio System - CD/DVD Precautions Adhesive Labels or Protective Disc Covers on CDs or DVDs: A Big Taboo NOTE: This article applies to all Honda models with a factory- or dealer-installed CD/DVD player or changer. We can't emphasize this enough: Never put adhesive labels or protective disc covers on recordable CDs or DVDs to be used in automotive CD/DVD players or changers. Here's why: ^ Recordable CDs and DVDs are actually thicker than their pre-recorded brethern. Automotive players and changers use rollers to draw the disc into the unit. The added thickness of an adhesive label or a protective disc cover can cause the disc to jam when it's loaded into or ejected from the unit. ^ CD/DVD players or changers are exposed to high temperatures inside the vehicle. High temperature can cause the label adhesive to soften. This can cause the label to curl on the edges and even form bubbles. Curled edges can catch on the rollers and bubbles add thickness to the disc. Either one can cause the disc to jam. To cut down on customer-caused damage, all '05 and later 0/Ms include this notice: Do not use CDs with adhesive labels. The label can curl up and cause the CD to jam in the unit. Anytime a service customer comes in with a loading or ejecting problem for a CD/DVD player or changer, ask if he or she used any discs with adhesive labels or protective disc covers. If the answer is yes, contact your DPSM for possible goodwill assistance. If the answer is no, then replace the audio unit under normal warranty. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compact Disc Player (CD): > 00-015 > Mar > 00 > Audio Unit with CD Player/Changer - Error Codes Compact Disc Player (CD): All Technical Service Bulletins Audio Unit with CD Player/Changer Error Codes 00-015 March 14, 2000 Applies To: All with CD Player/Changer Audio Unit Error Codes (Replaces 91-007, dated October 6, 1997) *If the audio unit displays an error code, use the troubleshooting tables in this service bulletin to troubleshoot the problem. Refer to service bulletin 98-019 for CD Player/Changer exchange information.* Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compact Disc Player (CD): > 00-015 > Mar > 00 > Audio Unit with CD Player/Changer - Error Codes > Page 8146 CD Changer Troubleshooting (All except Passport) CD Player Troubleshooting (All except Passport) Radio Troubleshooting (All except Passport) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compact Disc Player (CD): > 00-015 > Mar > 00 > Audio Unit with CD Player/Changer - Error Codes > Page 8147 CD Player/Changer Troubleshooting (Passport only) Manually Removing a Jammed Magazine (All except Passport) One-piece door model: 1. Remove the changer from the vehicle. 2. Remove the rear cover plate from the changer, and look for a jammed disc. 3. If a disc is jammed between the player and the magazine, turn the loading gear until the disc returns to the player mechanism. Do not attempt to reload the disc back into the magazine. 4. After the disc is loaded into the player mechanism, turn the changer so that the front is facing you. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compact Disc Player (CD): > 00-015 > Mar > 00 > Audio Unit with CD Player/Changer - Error Codes > Page 8148 5. Insert a thin stainless steel ruler or a "Slim Jim" under the magazine, about 1-1/2" from the right side of the opening. 6. Push the ruler in until it presses against the eject lever at the back of the unit. 7. Slowly remove the ruler and magazine at the same time. Two-piece door model: 1. Remove the changer from the vehicle. 2. Remove the top cover plate from the changer, and look for a jammed tray. 3. If a tray is stuck in the player, reinstall the cover and replace the changer. If all the trays are in the magazine, insert a thin stainless steel ruler or a "Slim Jim" under the magazine, about 1/2" from the right side of the opening. 4. Push the ruler in until it presses against the eject lever at the back of the unit. 5. Slowly remove the ruler and magazine at the same time. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compact Disc Player (CD): > 00-015 > Mar > 00 > Audio Unit with CD Player/Changer - Error Codes > Page 8149 Manually Removing a Jammed Magazine (Passport only) One-piece door model: 1. Open the changer door. 2. Check to see if all the trays are in the magazine. ^ If a tray is stuck in the changer, replace the changer. ^ If all the trays are in the magazine, place the changer in a horizontal position, and insert a thin stainless steel ruler or a "Slim Jim" under the magazine, about 1/2" from the right side of the opening. 3. Push the ruler in until it presses against the eject lever at the back of the unit. 4. Slowly remove the ruler and magazine at the same time. Two-piece door model: 1. Remove the changer from the vehicle. 2. Remove the top cover plate from the changer, and inspect for a jammed tray. ^ If a tray is stuck in the changer, replace the changer. ^ If all the trays are in the magazine, place the changer in a horizontal position, and insert a thin stainless steel ruler or a "Slim Jim" under the magazine, about 1/2" from the right side of the opening. 3. Push the ruler in until it presses against the eject lever at the back of the unit. 4. Slowly remove the ruler and magazine at the same time. Handling and Inspecting Compact Discs Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compact Disc Player (CD): > 00-015 > Mar > 00 > Audio Unit with CD Player/Changer - Error Codes > Page 8150 ^ Handle a CD by its edges; never touch the flat surfaces. Contamination from fingerprints, liquids, felt-tip pens, and labels can cause the CD to not play properly, or possibly jam in the drive. ^ When cleaning a disc, use a clean soft cloth. Wipe across the disc from the center to the outside. Do not wipe the disc in a circular motion. ^ A new CD may be rough on the inner and outer edges. The small plastic pieces causing this roughness can flake off and fall on the recording surface of the disc, causing skipping or other problems. Remove these pieces by rubbing the inner and outer edges with the side of a pencil or pen. ^ Various accessories are available to protect CDs and improve the sound quality of CDs. These accessories increase the thickness or diameter of the discs, and should not be used in CD changers. Disclaimer Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Compact Disc Player (CD): > SN051000-07 > Oct > 05 > Audio System - CD/DVD Precautions Compact Disc Player (CD): All Technical Service Bulletins Audio System - CD/DVD Precautions Adhesive Labels or Protective Disc Covers on CDs or DVDs: A Big Taboo NOTE: This article applies to all Honda models with a factory- or dealer-installed CD/DVD player or changer. We can't emphasize this enough: Never put adhesive labels or protective disc covers on recordable CDs or DVDs to be used in automotive CD/DVD players or changers. Here's why: ^ Recordable CDs and DVDs are actually thicker than their pre-recorded brethern. Automotive players and changers use rollers to draw the disc into the unit. The added thickness of an adhesive label or a protective disc cover can cause the disc to jam when it's loaded into or ejected from the unit. ^ CD/DVD players or changers are exposed to high temperatures inside the vehicle. High temperature can cause the label adhesive to soften. This can cause the label to curl on the edges and even form bubbles. Curled edges can catch on the rollers and bubbles add thickness to the disc. Either one can cause the disc to jam. To cut down on customer-caused damage, all '05 and later 0/Ms include this notice: Do not use CDs with adhesive labels. The label can curl up and cause the CD to jam in the unit. Anytime a service customer comes in with a loading or ejecting problem for a CD/DVD player or changer, ask if he or she used any discs with adhesive labels or protective disc covers. If the answer is yes, contact your DPSM for possible goodwill assistance. If the answer is no, then replace the audio unit under normal warranty. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Technical Service Bulletins > Page 8156 Compact Disc Player (CD): Service and Repair NOTE: The original radio has a coded theft protection circuit. Be sure to get the customer's code number before - disconnecting the battery. - removing the radio fuse from the under-hood fuse/relay box. - removing the radio. After service, reconnect power to the radio and turn it on. When the word "CODE" is displayed, enter the customer's 5-digit code to restore radio operation. Refer to the TSB listed below for information on how to obtain the code in the event the customer does not have the code. TSB # 98-026 April 15, 1998 Applies To: ALL with Anti-Theft Audio Units Audio Unit Anti-Theft Code Labels BACKGROUND This service bulletin describes where to attach the audio unit anti-theft labels that come in the glove box of vehicles equipped with anti-theft audio systems. If a vehicle has an anti-theft audio system, there are three peel-off labels in the glove box. Two of the labels have both the anti-theft code and the audio unit's serial number, and a third label contains only the serial number for the audio unit. During Pre Delivery Inspection, stick the label with only the serial number on the glove box. If the radio code ever needs to be retrieved through the HONDANET 2000 system, this will save you the time and labor of removing the audio unit to record the serial number. NOTES: - Also perform this procedure when installing an accessory audio unit that is equipped with an anti-theft system. - If a remanufactured audio unit is installed in a vehicle, remove the old labels and install new ones on the glove box, Radio Identification Card, and the vehicle's service records. - If the glove box is ever replaced, transfer the labels from the old glove box to the new one. WARRANTY CLAIM INFORMATION None. This bulletin is for information only. Skill level: Maintenance Technician PROCEDURE Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Technical Service Bulletins > Page 8157 1. Stick the label containing only the serial number information on the glove box. 2. Stick the remaining two labels on the Anti-Theft Radio Identification Card and on the vehicle's service records. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Service and Repair Radio/Stereo: Service and Repair NOTE:The original radio has a coded theft protection circuit. Be sure to get the customer's code number before - disconnecting the battery. - removing the radio fuse from the under-hood fuse/relay box. - removing the radio. After service, reconnect power to the radio and turn it on. When the word "CODE" is displayed, enter the customer's 5-digit code to restore radio operation. For information on how to obtain the code in the event the customer does not have the code please refer to the TSB below. TSB # 98-026 April 15, 1998 Applies To: ALL with Anti-Theft Audio Units Audio Unit Anti-Theft Code Labels BACKGROUND This service bulletin describes where to attach the audio unit anti-theft labels that come in the glove box of vehicles equipped with anti-theft audio systems. If a vehicle has an anti-theft audio system, there are three peel-off labels in the glove box. Two of the labels have both the anti-theft code and the audio unit's serial number, and a third label contains only the serial number for the audio unit. During Pre Delivery Inspection, stick the label with only the serial number on the glove box. If the radio code ever needs to be retrieved through the HONDANET 2000 system, this will save you the time and labor of removing the audio unit to record the serial number. NOTES: - Also perform this procedure when installing an accessory audio unit that is equipped with an anti-theft system. - If a remanufactured audio unit is installed in a vehicle, remove the old labels and install new ones on the glove box, Radio Identification Card, and the vehicle's service records. - If the glove box is ever replaced, transfer the labels from the old glove box to the new one. WARRANTY CLAIM INFORMATION None. This bulletin is for information only. Skill level: Maintenance Technician PROCEDURE Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Service and Repair > Page 8161 1. Stick the label containing only the serial number information on the glove box. 2. Stick the remaining two labels on the Anti-Theft Radio Identification Card and on the vehicle's service records. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Service and Repair Tape Player: Service and Repair NOTE:The original radio has a coded theft protection circuit. Be sure to get the customer's code number before - disconnecting the battery. - removing the radio fuse from the under-hood fuse/relay box. - removing the radio. After service, reconnect power to the radio and turn it on. When the word "CODE" is displayed, enter the customer's 5-digit code to restore radio operation. Refer to the TSB listed below for information on how to obtain the code in the event the customer does not have the code. TSB # 98-026 April 15, 1998 Applies To: ALL with Anti-Theft Audio Units Audio Unit Anti-Theft Code Labels BACKGROUND This service bulletin describes where to attach the audio unit anti-theft labels that come in the glove box of vehicles equipped with anti-theft audio systems. If a vehicle has an anti-theft audio system, there are three peel-off labels in the glove box. Two of the labels have both the anti-theft code and the audio unit's serial number, and a third label contains only the serial number for the audio unit. During Pre Delivery Inspection, stick the label with only the serial number on the glove box. If the radio code ever needs to be retrieved through the HONDANET 2000 system, this will save you the time and labor of removing the audio unit to record the serial number. NOTES: - Also perform this procedure when installing an accessory audio unit that is equipped with an anti-theft system. - If a remanufactured audio unit is installed in a vehicle, remove the old labels and install new ones on the glove box, Radio Identification Card, and the vehicle's service records. - If the glove box is ever replaced, transfer the labels from the old glove box to the new one. WARRANTY CLAIM INFORMATION None. This bulletin is for information only. Skill level: Maintenance Technician PROCEDURE Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Service and Repair > Page 8165 1. Stick the label containing only the serial number information on the glove box. 2. Stick the remaining two labels on the Anti-Theft Radio Identification Card and on the vehicle's service records. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Locations Body Control Module: Locations Rear Of Under-dash Fuse/Relay Box Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8173 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8174 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8175 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8176 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8177 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8178 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8179 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8180 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8181 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8182 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8183 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8184 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8185 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8186 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8187 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8188 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8189 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8190 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8191 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8192 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8193 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8194 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8195 Body Control Module: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8196 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8197 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8198 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8199 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8200 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8201 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8202 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8203 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8204 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8205 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8206 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8207 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8208 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8209 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8210 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8211 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8212 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8213 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8214 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8215 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8216 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8217 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8218 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8219 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8220 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8221 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair Front Door Latch: Service and Repair Door Latch Replacement NOTE: Raise the window fully. 1. Remove: - Door panel - Plastic cover - Rear channel 2. Pry the door handle latch rod and lock rod out of its joint using a flat tip screwdriver. Disconnect the connectors from the door. Remove the mounting screws, then remove the latch assembly through the hole in the door. NOTE: - Take care not to bend the rods. - To ease reassembly, note the location (A) of the rod on the joint before disconnecting it. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair > Page 8228 3. Installation is the reverse of the removal procedure. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Customer Interest for Front Door Panel: > 95037 > Nov > 95 > Interior - Door Panel Center Pad Is Worn/Bubbled Front Door Panel: Customer Interest Interior - Door Panel Center Pad Is Worn/Bubbled Bulletin No. 95-037 Issue Date NOV 6, 1995 Model 1992-95 CIVIC Applicable To 4-DOOR (Japan Production Only) File Under BODY Door Panel Center Pad Is Worn or Bubbled SYMPTOM The fabric covering the door panel center pad wears prematurely or pulls away (bubbles up) from its backing material. PROBABLE CAUSE Not enough adhesive between the center pad's fabric and its backing material. CORRECTIVE ACTION Replace the door panel center pad. 1. Remove the door panel. (Refer to section 20 of the appropriate Civic Service Manual.) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Customer Interest for Front Door Panel: > 95037 > Nov > 95 > Interior - Door Panel Center Pad Is Worn/Bubbled > Page 8237 2. If you are working on a front door panel, remove the power window switch. 3. Cover your workbench with a protective cloth, then place the door panel upside down on the cloth. 4. While wearing eye protection, drill a 5/16-inch hole through the center of each heat-bonded boss. (The bosses attach the center pad to the door panel.) Front door center pads have 14 bosses; rear door center pads have 17. 5. Pull off and discard the pad. If needed, use a pair of diagonal cutters to remove any material remaining on the bosses. 6. Fit the new pad into the door panel opening. 7. With the door panel upside down, support the pad with a block of wood placed between the workbench and the protective cloth. (Do not set the Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Customer Interest for Front Door Panel: > 95037 > Nov > 95 > Interior - Door Panel Center Pad Is Worn/Bubbled > Page 8238 pad directly on the wood.) 8. Using a 10 mm socket and a hammer, carefully tap the push nuts onto each boss. (Push nuts are included with the new pad.) 9. Cut off the excess boss material with a pair of diagonal cutters. Leave about 5 mm (0.2 inches) of material above each push nut. 10. If you are working on the driver's door panel, reinstall the power window switch. 11. Reinstall the door panel. (Refer to section 20 of the appropriate Civic Service Manual.) PARTS INFORMATION Refer to Parts Information Bulletin A95-0053 for the center pad part numbers. When ordering, be sure to use the correct car year, model, center pad color, and door position. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. OPERATION NUMBERDESCRIPTION FLAT RATE TIME 843102 Replace front door 0.8 hour center pad Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Customer Interest for Front Door Panel: > 95037 > Nov > 95 > Interior - Door Panel Center Pad Is Worn/Bubbled > Page 8239 845102 Replace rear door 0.9 hour center pad Failed part: Front: P/N 83533-SR4-A01ZC H/C 4486197 Failed part: Rear: P/N 83700-SR4-A00ZA H/C 3896917 Defect code: 005 Contention code: A01 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > 95037 > Nov > 95 > Interior - Door Panel Center Pad Is Worn/Bubbled Front Door Panel: All Technical Service Bulletins Interior - Door Panel Center Pad Is Worn/Bubbled Bulletin No. 95-037 Issue Date NOV 6, 1995 Model 1992-95 CIVIC Applicable To 4-DOOR (Japan Production Only) File Under BODY Door Panel Center Pad Is Worn or Bubbled SYMPTOM The fabric covering the door panel center pad wears prematurely or pulls away (bubbles up) from its backing material. PROBABLE CAUSE Not enough adhesive between the center pad's fabric and its backing material. CORRECTIVE ACTION Replace the door panel center pad. 1. Remove the door panel. (Refer to section 20 of the appropriate Civic Service Manual.) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > 95037 > Nov > 95 > Interior - Door Panel Center Pad Is Worn/Bubbled > Page 8245 2. If you are working on a front door panel, remove the power window switch. 3. Cover your workbench with a protective cloth, then place the door panel upside down on the cloth. 4. While wearing eye protection, drill a 5/16-inch hole through the center of each heat-bonded boss. (The bosses attach the center pad to the door panel.) Front door center pads have 14 bosses; rear door center pads have 17. 5. Pull off and discard the pad. If needed, use a pair of diagonal cutters to remove any material remaining on the bosses. 6. Fit the new pad into the door panel opening. 7. With the door panel upside down, support the pad with a block of wood placed between the workbench and the protective cloth. (Do not set the Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > 95037 > Nov > 95 > Interior - Door Panel Center Pad Is Worn/Bubbled > Page 8246 pad directly on the wood.) 8. Using a 10 mm socket and a hammer, carefully tap the push nuts onto each boss. (Push nuts are included with the new pad.) 9. Cut off the excess boss material with a pair of diagonal cutters. Leave about 5 mm (0.2 inches) of material above each push nut. 10. If you are working on the driver's door panel, reinstall the power window switch. 11. Reinstall the door panel. (Refer to section 20 of the appropriate Civic Service Manual.) PARTS INFORMATION Refer to Parts Information Bulletin A95-0053 for the center pad part numbers. When ordering, be sure to use the correct car year, model, center pad color, and door position. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. OPERATION NUMBERDESCRIPTION FLAT RATE TIME 843102 Replace front door 0.8 hour center pad Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > 95037 > Nov > 95 > Interior - Door Panel Center Pad Is Worn/Bubbled > Page 8247 845102 Replace rear door 0.9 hour center pad Failed part: Front: P/N 83533-SR4-A01ZC H/C 4486197 Failed part: Rear: P/N 83700-SR4-A00ZA H/C 3896917 Defect code: 005 Contention code: A01 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 8248 Front Door Panel: By Symptom Technical Service Bulletin # 95037 Date: 951106 Interior - Door Panel Center Pad Is Worn/Bubbled Bulletin No. 95-037 Issue Date NOV 6, 1995 Model 1992-95 CIVIC Applicable To 4-DOOR (Japan Production Only) File Under BODY Door Panel Center Pad Is Worn or Bubbled SYMPTOM The fabric covering the door panel center pad wears prematurely or pulls away (bubbles up) from its backing material. PROBABLE CAUSE Not enough adhesive between the center pad's fabric and its backing material. CORRECTIVE ACTION Replace the door panel center pad. 1. Remove the door panel. (Refer to section 20 of the appropriate Civic Service Manual.) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 8249 2. If you are working on a front door panel, remove the power window switch. 3. Cover your workbench with a protective cloth, then place the door panel upside down on the cloth. 4. While wearing eye protection, drill a 5/16-inch hole through the center of each heat-bonded boss. (The bosses attach the center pad to the door panel.) Front door center pads have 14 bosses; rear door center pads have 17. 5. Pull off and discard the pad. If needed, use a pair of diagonal cutters to remove any material remaining on the bosses. 6. Fit the new pad into the door panel opening. 7. With the door panel upside down, support the pad with a block of wood placed between the workbench and the protective cloth. (Do not set the Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 8250 pad directly on the wood.) 8. Using a 10 mm socket and a hammer, carefully tap the push nuts onto each boss. (Push nuts are included with the new pad.) 9. Cut off the excess boss material with a pair of diagonal cutters. Leave about 5 mm (0.2 inches) of material above each push nut. 10. If you are working on the driver's door panel, reinstall the power window switch. 11. Reinstall the door panel. (Refer to section 20 of the appropriate Civic Service Manual.) PARTS INFORMATION Refer to Parts Information Bulletin A95-0053 for the center pad part numbers. When ordering, be sure to use the correct car year, model, center pad color, and door position. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. OPERATION NUMBERDESCRIPTION FLAT RATE TIME 843102 Replace front door 0.8 hour center pad Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 8251 845102 Replace rear door 0.9 hour center pad Failed part: Front: P/N 83533-SR4-A01ZC H/C 4486197 Failed part: Rear: P/N 83700-SR4-A00ZA H/C 3896917 Defect code: 005 Contention code: A01 Technical Service Bulletin # 95037 Date: 951106 Interior - Door Panel Center Pad Is Worn/Bubbled Bulletin No. 95-037 Issue Date NOV 6, 1995 Model 1992-95 CIVIC Applicable To 4-DOOR (Japan Production Only) File Under BODY Door Panel Center Pad Is Worn or Bubbled SYMPTOM The fabric covering the door panel center pad wears prematurely or pulls away (bubbles up) from its backing material. PROBABLE CAUSE Not enough adhesive between the center pad's fabric and its backing material. CORRECTIVE ACTION Replace the door panel center pad. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 8252 1. Remove the door panel. (Refer to section 20 of the appropriate Civic Service Manual.) 2. If you are working on a front door panel, remove the power window switch. 3. Cover your workbench with a protective cloth, then place the door panel upside down on the cloth. 4. While wearing eye protection, drill a 5/16-inch hole through the center of each heat-bonded boss. (The bosses attach the center pad to the door panel.) Front door center pads have 14 bosses; rear door center pads have 17. 5. Pull off and discard the pad. If needed, use a pair of diagonal cutters to remove any material remaining on the bosses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 8253 6. Fit the new pad into the door panel opening. 7. With the door panel upside down, support the pad with a block of wood placed between the workbench and the protective cloth. (Do not set the pad directly on the wood.) 8. Using a 10 mm socket and a hammer, carefully tap the push nuts onto each boss. (Push nuts are included with the new pad.) 9. Cut off the excess boss material with a pair of diagonal cutters. Leave about 5 mm (0.2 inches) of material above each push nut. 10. If you are working on the driver's door panel, reinstall the power window switch. 11. Reinstall the door panel. (Refer to section 20 of the appropriate Civic Service Manual.) PARTS INFORMATION Refer to Parts Information Bulletin A95-0053 for the center pad part numbers. When ordering, be sure to use the correct car year, model, center pad color, and door position. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 8254 OPERATION NUMBERDESCRIPTION FLAT RATE TIME 843102 Replace front door 0.8 hour center pad 845102 Replace rear door 0.9 hour center pad Failed part: Front: P/N 83533-SR4-A01ZC H/C 4486197 Failed part: Rear: P/N 83700-SR4-A00ZA H/C 3896917 Defect code: 005 Contention code: A01 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Page 8255 Front Door Panel: Service and Repair Door Panel/Plastic Cover Replacemen If applicable, remove the regulator handle by pulling the clip out with a wire hook. 2. Remove the screw, then pull the inner handle out half-way and disconnect the inner handle rod and power door lock connector. Remove the screw, then remove the inner handle trim while pulling the inner handle. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Page 8256 3. Remove the screw, then remove the armrest pocket. If applicable, disconnect the power window connector (2D). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Page 8257 Doors Door Panel/Plastic Cover Replacement 4. Remove the clips attaching the door panel (see trim pad remover). Remove the door panel by pulling it upward. If applicable, disconnect the following: - Power window connector (40) - Power door lock connector (2D driver's) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Page 8258 - Tweeter connector (2D EX option) NOTE: Remove the door panel with as little bending as possible to avoid creasing or breaking it. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Page 8259 5. Remove the grommets, bracket, door lock unit (4D/2D) and inner handle (3D/2D), then carefully remove the plastic cover. 6. Install the door panel and plastic cover in the reverse order of removal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Page 8260 NOTE: Make sure the door harness and connectors are fastened correctly on the door. Door Panel/Plastic Cover Replacement Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Page 8261 Apply adhesive along the edge where necessary to maintain a continuous seal and prevent water leaks Before fastening the door panel, make sure the door harness is not pinched. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Locations Front Door Window Motor: Locations Middle Of Driver's Door (Right Front Similar) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > Customer Interest for Rear Door Panel: > 95037 > Nov > 95 > Interior - Door Panel Center Pad Is Worn/Bubbled Rear Door Panel: Customer Interest Interior - Door Panel Center Pad Is Worn/Bubbled Bulletin No. 95-037 Issue Date NOV 6, 1995 Model 1992-95 CIVIC Applicable To 4-DOOR (Japan Production Only) File Under BODY Door Panel Center Pad Is Worn or Bubbled SYMPTOM The fabric covering the door panel center pad wears prematurely or pulls away (bubbles up) from its backing material. PROBABLE CAUSE Not enough adhesive between the center pad's fabric and its backing material. CORRECTIVE ACTION Replace the door panel center pad. 1. Remove the door panel. (Refer to section 20 of the appropriate Civic Service Manual.) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > Customer Interest for Rear Door Panel: > 95037 > Nov > 95 > Interior - Door Panel Center Pad Is Worn/Bubbled > Page 8274 2. If you are working on a front door panel, remove the power window switch. 3. Cover your workbench with a protective cloth, then place the door panel upside down on the cloth. 4. While wearing eye protection, drill a 5/16-inch hole through the center of each heat-bonded boss. (The bosses attach the center pad to the door panel.) Front door center pads have 14 bosses; rear door center pads have 17. 5. Pull off and discard the pad. If needed, use a pair of diagonal cutters to remove any material remaining on the bosses. 6. Fit the new pad into the door panel opening. 7. With the door panel upside down, support the pad with a block of wood placed between the workbench and the protective cloth. (Do not set the Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > Customer Interest for Rear Door Panel: > 95037 > Nov > 95 > Interior - Door Panel Center Pad Is Worn/Bubbled > Page 8275 pad directly on the wood.) 8. Using a 10 mm socket and a hammer, carefully tap the push nuts onto each boss. (Push nuts are included with the new pad.) 9. Cut off the excess boss material with a pair of diagonal cutters. Leave about 5 mm (0.2 inches) of material above each push nut. 10. If you are working on the driver's door panel, reinstall the power window switch. 11. Reinstall the door panel. (Refer to section 20 of the appropriate Civic Service Manual.) PARTS INFORMATION Refer to Parts Information Bulletin A95-0053 for the center pad part numbers. When ordering, be sure to use the correct car year, model, center pad color, and door position. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. OPERATION NUMBERDESCRIPTION FLAT RATE TIME 843102 Replace front door 0.8 hour center pad Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > Customer Interest for Rear Door Panel: > 95037 > Nov > 95 > Interior - Door Panel Center Pad Is Worn/Bubbled > Page 8276 845102 Replace rear door 0.9 hour center pad Failed part: Front: P/N 83533-SR4-A01ZC H/C 4486197 Failed part: Rear: P/N 83700-SR4-A00ZA H/C 3896917 Defect code: 005 Contention code: A01 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Panel: > 95037 > Nov > 95 > Interior - Door Panel Center Pad Is Worn/Bubbled Rear Door Panel: All Technical Service Bulletins Interior - Door Panel Center Pad Is Worn/Bubbled Bulletin No. 95-037 Issue Date NOV 6, 1995 Model 1992-95 CIVIC Applicable To 4-DOOR (Japan Production Only) File Under BODY Door Panel Center Pad Is Worn or Bubbled SYMPTOM The fabric covering the door panel center pad wears prematurely or pulls away (bubbles up) from its backing material. PROBABLE CAUSE Not enough adhesive between the center pad's fabric and its backing material. CORRECTIVE ACTION Replace the door panel center pad. 1. Remove the door panel. (Refer to section 20 of the appropriate Civic Service Manual.) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Panel: > 95037 > Nov > 95 > Interior - Door Panel Center Pad Is Worn/Bubbled > Page 8282 2. If you are working on a front door panel, remove the power window switch. 3. Cover your workbench with a protective cloth, then place the door panel upside down on the cloth. 4. While wearing eye protection, drill a 5/16-inch hole through the center of each heat-bonded boss. (The bosses attach the center pad to the door panel.) Front door center pads have 14 bosses; rear door center pads have 17. 5. Pull off and discard the pad. If needed, use a pair of diagonal cutters to remove any material remaining on the bosses. 6. Fit the new pad into the door panel opening. 7. With the door panel upside down, support the pad with a block of wood placed between the workbench and the protective cloth. (Do not set the Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Panel: > 95037 > Nov > 95 > Interior - Door Panel Center Pad Is Worn/Bubbled > Page 8283 pad directly on the wood.) 8. Using a 10 mm socket and a hammer, carefully tap the push nuts onto each boss. (Push nuts are included with the new pad.) 9. Cut off the excess boss material with a pair of diagonal cutters. Leave about 5 mm (0.2 inches) of material above each push nut. 10. If you are working on the driver's door panel, reinstall the power window switch. 11. Reinstall the door panel. (Refer to section 20 of the appropriate Civic Service Manual.) PARTS INFORMATION Refer to Parts Information Bulletin A95-0053 for the center pad part numbers. When ordering, be sure to use the correct car year, model, center pad color, and door position. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. OPERATION NUMBERDESCRIPTION FLAT RATE TIME 843102 Replace front door 0.8 hour center pad Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Panel: > 95037 > Nov > 95 > Interior - Door Panel Center Pad Is Worn/Bubbled > Page 8284 845102 Replace rear door 0.9 hour center pad Failed part: Front: P/N 83533-SR4-A01ZC H/C 4486197 Failed part: Rear: P/N 83700-SR4-A00ZA H/C 3896917 Defect code: 005 Contention code: A01 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Panel: > Page 8285 Rear Door Panel: By Symptom Technical Service Bulletin # 95037 Date: 951106 Interior - Door Panel Center Pad Is Worn/Bubbled Bulletin No. 95-037 Issue Date NOV 6, 1995 Model 1992-95 CIVIC Applicable To 4-DOOR (Japan Production Only) File Under BODY Door Panel Center Pad Is Worn or Bubbled SYMPTOM The fabric covering the door panel center pad wears prematurely or pulls away (bubbles up) from its backing material. PROBABLE CAUSE Not enough adhesive between the center pad's fabric and its backing material. CORRECTIVE ACTION Replace the door panel center pad. 1. Remove the door panel. (Refer to section 20 of the appropriate Civic Service Manual.) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Panel: > Page 8286 2. If you are working on a front door panel, remove the power window switch. 3. Cover your workbench with a protective cloth, then place the door panel upside down on the cloth. 4. While wearing eye protection, drill a 5/16-inch hole through the center of each heat-bonded boss. (The bosses attach the center pad to the door panel.) Front door center pads have 14 bosses; rear door center pads have 17. 5. Pull off and discard the pad. If needed, use a pair of diagonal cutters to remove any material remaining on the bosses. 6. Fit the new pad into the door panel opening. 7. With the door panel upside down, support the pad with a block of wood placed between the workbench and the protective cloth. (Do not set the Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Panel: > Page 8287 pad directly on the wood.) 8. Using a 10 mm socket and a hammer, carefully tap the push nuts onto each boss. (Push nuts are included with the new pad.) 9. Cut off the excess boss material with a pair of diagonal cutters. Leave about 5 mm (0.2 inches) of material above each push nut. 10. If you are working on the driver's door panel, reinstall the power window switch. 11. Reinstall the door panel. (Refer to section 20 of the appropriate Civic Service Manual.) PARTS INFORMATION Refer to Parts Information Bulletin A95-0053 for the center pad part numbers. When ordering, be sure to use the correct car year, model, center pad color, and door position. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. OPERATION NUMBERDESCRIPTION FLAT RATE TIME 843102 Replace front door 0.8 hour center pad Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Panel: > Page 8288 845102 Replace rear door 0.9 hour center pad Failed part: Front: P/N 83533-SR4-A01ZC H/C 4486197 Failed part: Rear: P/N 83700-SR4-A00ZA H/C 3896917 Defect code: 005 Contention code: A01 Technical Service Bulletin # 95037 Date: 951106 Interior - Door Panel Center Pad Is Worn/Bubbled Bulletin No. 95-037 Issue Date NOV 6, 1995 Model 1992-95 CIVIC Applicable To 4-DOOR (Japan Production Only) File Under BODY Door Panel Center Pad Is Worn or Bubbled SYMPTOM The fabric covering the door panel center pad wears prematurely or pulls away (bubbles up) from its backing material. PROBABLE CAUSE Not enough adhesive between the center pad's fabric and its backing material. CORRECTIVE ACTION Replace the door panel center pad. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Panel: > Page 8289 1. Remove the door panel. (Refer to section 20 of the appropriate Civic Service Manual.) 2. If you are working on a front door panel, remove the power window switch. 3. Cover your workbench with a protective cloth, then place the door panel upside down on the cloth. 4. While wearing eye protection, drill a 5/16-inch hole through the center of each heat-bonded boss. (The bosses attach the center pad to the door panel.) Front door center pads have 14 bosses; rear door center pads have 17. 5. Pull off and discard the pad. If needed, use a pair of diagonal cutters to remove any material remaining on the bosses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Panel: > Page 8290 6. Fit the new pad into the door panel opening. 7. With the door panel upside down, support the pad with a block of wood placed between the workbench and the protective cloth. (Do not set the pad directly on the wood.) 8. Using a 10 mm socket and a hammer, carefully tap the push nuts onto each boss. (Push nuts are included with the new pad.) 9. Cut off the excess boss material with a pair of diagonal cutters. Leave about 5 mm (0.2 inches) of material above each push nut. 10. If you are working on the driver's door panel, reinstall the power window switch. 11. Reinstall the door panel. (Refer to section 20 of the appropriate Civic Service Manual.) PARTS INFORMATION Refer to Parts Information Bulletin A95-0053 for the center pad part numbers. When ordering, be sure to use the correct car year, model, center pad color, and door position. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Panel: > Page 8291 OPERATION NUMBERDESCRIPTION FLAT RATE TIME 843102 Replace front door 0.8 hour center pad 845102 Replace rear door 0.9 hour center pad Failed part: Front: P/N 83533-SR4-A01ZC H/C 4486197 Failed part: Rear: P/N 83700-SR4-A00ZA H/C 3896917 Defect code: 005 Contention code: A01 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > System Information > Service and Repair Rear Door Window Glass: Service and Repair Glass/Regulator Replacement 1. Remove: - Door panel - Plastic cover - Corner sash trim 2. Remove the mounting not and mounting bolt attaching the rear channel. 3. Carefully move the glass until you can see the glass mounting bolts, then remove them. Carefully pull the glass out through the window slot. NOTE: - Take care not to drop the glass inside the door. - Take care not to damage locations (A) of the glass run channel. 4. Peel the glass run channel Out of the rear channel, then remove the rear channel. NOTE: After installing the rear channel, make sure the glass run channel is not twisted. NOTE: To install, the glass run channel, fit it into the reat channel an shown. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > System Information > Service and Repair > Page 8295 5. Remove the two mounting bolts. Loosen the mounting bolt and three motor bolts. Disconnect the connector (power window model). Remove the regulator through the center hole in the door. 6. Grease all the sliding surfaces of the regulator where shown. Check that the regulator moves smoothly by connecting the regulator handle or a 12 V battery to the power window motor. 7. Installation is the reverse of the removal procedure. 8. Roll the glass up and down to see if it moves freely without binding. Also make sure that there is no clearance between the glass and glass run channel when the glass is closed. Adjust the position of the glass as necessary. 9. Attach the door harness to the door correctly. 10. When reinstalling the plastic cover, apply adhesive along the edge where necessary to maintain a contentious seal and prevent water leaks. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Locations Rear Door Window Motor: Locations Front Of Left Rear Door (Right Similar) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Locations > Page 8299 Rear Door Window Motor: Service and Repair Glass/Regulator Replacement 1. Remove: - Door panel - Plastic cover - Corner sash trim 2. Remove the mounting not and mounting bolt attaching the rear channel. 3. Carefully move the glass until you can see the glass mounting bolts, then remove them. Carefully pull the glass out through the window slot. NOTE: - Take care not to drop the glass inside the door. - Take care not to damage locations (A) of the glass run channel. 4. Peel the glass run channel Out of the rear channel, then remove the rear channel. NOTE: After installing the rear channel, make sure the glass run channel is not twisted. NOTE: To install, the glass run channel, fit it into the reat channel an shown. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Locations > Page 8300 5. Remove the two mounting bolts. Loosen the mounting bolt and three motor bolts. Disconnect the connector (power window model). Remove the regulator through the center hole in the door. 6. Grease all the sliding surfaces of the regulator where shown. Check that the regulator moves smoothly by connecting the regulator handle or a 12 V battery to the power window motor. 7. Installation is the reverse of the removal procedure. 8. Roll the glass up and down to see if it moves freely without binding. Also make sure that there is no clearance between the glass and glass run channel when the glass is closed. Adjust the position of the glass as necessary. 9. Attach the door harness to the door correctly. 10. When reinstalling the plastic cover, apply adhesive along the edge where necessary to maintain a contentious seal and prevent water leaks. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair Rear Door Window Regulator: Service and Repair Glass/Regulator Replacement 1. Remove: - Door panel - Plastic cover - Corner sash trim 2. Remove the mounting not and mounting bolt attaching the rear channel. 3. Carefully move the glass until you can see the glass mounting bolts, then remove them. Carefully pull the glass out through the window slot. NOTE: - Take care not to drop the glass inside the door. - Take care not to damage locations (A) of the glass run channel. 4. Peel the glass run channel Out of the rear channel, then remove the rear channel. NOTE: After installing the rear channel, make sure the glass run channel is not twisted. NOTE: To install, the glass run channel, fit it into the reat channel an shown. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Page 8304 5. Remove the two mounting bolts. Loosen the mounting bolt and three motor bolts. Disconnect the connector (power window model). Remove the regulator through the center hole in the door. 6. Grease all the sliding surfaces of the regulator where shown. Check that the regulator moves smoothly by connecting the regulator handle or a 12 V battery to the power window motor. 7. Installation is the reverse of the removal procedure. 8. Roll the glass up and down to see if it moves freely without binding. Also make sure that there is no clearance between the glass and glass run channel when the glass is closed. Adjust the position of the glass as necessary. 9. Attach the door harness to the door correctly. 10. When reinstalling the plastic cover, apply adhesive along the edge where necessary to maintain a contentious seal and prevent water leaks. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Technical Service Bulletins > Customer Interest for Fuel Door: > 94020 > Jul > 94 > Body - Fuel Fill Door Doesn't Open Fuel Door: Customer Interest Body - Fuel Fill Door Doesn't Open BULLETIN NO. 94-020 ISSUE DATE JULY 24, 1995 MODEL: [NEW] 1994 ACCORD 1992-95 CIVIC (Except del Sol) 1993-94 PRELUDE APPLICABLE TO See VEHICLES AFFECTED FILE UNDER BODY Fuel Fill Door Does Not Open (Supersedes 94-020, dated June 24, 1994) PROBLEM The fuel fill door does not open far enough to clear the body. VEHICLES AFFECTED 1994 ACCORD: Sedan -Thru VIN JHMCD5...RC040100 -Thru VIN 1HGCD5...f1A070396 COUPE -Thru VIN 1HGCD7...RA015O98 Wagon -ALL 1992-95 Civic-ALL [NEW] 1993-94 Prelude-ALL CORRECTIVE ACTION Align the fuel fill door, and install a spring boot or shim (see PARTS INFORMATION). 1. Check the gap between the fuel fill door and the opening in the quarter panel. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Technical Service Bulletins > Customer Interest for Fuel Door: > 94020 > Jul > 94 > Body - Fuel Fill Door Doesn't Open > Page 8313 2. If necessary, loosen the hinge bolts for the fuel fill door. Adjust the door and retighten the bolts. ACCORD 3. Install the boot over the spring tab for the fuel fill door. 4. Test the operation of the fuel fill door. PRELUDE 3. Before installing the boot, apply a small amount of 3M Weatherstrip Adhesive (Black), 3M P/N 051135-08011, to the spring tab. 4. Test the operation of the fuel fill door. CIVIC Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Technical Service Bulletins > Customer Interest for Fuel Door: > 94020 > Jul > 94 > Body - Fuel Fill Door Doesn't Open > Page 8314 3. Clean the inside of the fuel fill door behind the stiffener with 3M General Purpose Adhesive Cleaner, 3M P/N 051135-08984. 4. Install the shim between the door stiffener and the door. Place the shim between the legs of the spring tab. 5. Test the operation of the fuel fill door. PARTS INFORMATION Fuel fill door spring boot: Accord P/N 63910-SV4-999, H/C 4561817 Prelude P/N 63910-SR4-999, H/C 4561809 Fuel fill door shim: Civic P/N 90550-SR4-999, H/C 4825220 [NEW] WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. Operation number: 849102 Flat rate time: 0.3 hour Failed part: P/N 74494-SM4-010 H/C 3820594 Defect code: 032 Contention code: B01 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Door: > 94020 > Jul > 94 > Body - Fuel Fill Door Doesn't Open Fuel Door: All Technical Service Bulletins Body - Fuel Fill Door Doesn't Open BULLETIN NO. 94-020 ISSUE DATE JULY 24, 1995 MODEL: [NEW] 1994 ACCORD 1992-95 CIVIC (Except del Sol) 1993-94 PRELUDE APPLICABLE TO See VEHICLES AFFECTED FILE UNDER BODY Fuel Fill Door Does Not Open (Supersedes 94-020, dated June 24, 1994) PROBLEM The fuel fill door does not open far enough to clear the body. VEHICLES AFFECTED 1994 ACCORD: Sedan -Thru VIN JHMCD5...RC040100 -Thru VIN 1HGCD5...f1A070396 COUPE -Thru VIN 1HGCD7...RA015O98 Wagon -ALL 1992-95 Civic-ALL [NEW] 1993-94 Prelude-ALL CORRECTIVE ACTION Align the fuel fill door, and install a spring boot or shim (see PARTS INFORMATION). 1. Check the gap between the fuel fill door and the opening in the quarter panel. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Door: > 94020 > Jul > 94 > Body - Fuel Fill Door Doesn't Open > Page 8320 2. If necessary, loosen the hinge bolts for the fuel fill door. Adjust the door and retighten the bolts. ACCORD 3. Install the boot over the spring tab for the fuel fill door. 4. Test the operation of the fuel fill door. PRELUDE 3. Before installing the boot, apply a small amount of 3M Weatherstrip Adhesive (Black), 3M P/N 051135-08011, to the spring tab. 4. Test the operation of the fuel fill door. CIVIC Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Door: > 94020 > Jul > 94 > Body - Fuel Fill Door Doesn't Open > Page 8321 3. Clean the inside of the fuel fill door behind the stiffener with 3M General Purpose Adhesive Cleaner, 3M P/N 051135-08984. 4. Install the shim between the door stiffener and the door. Place the shim between the legs of the spring tab. 5. Test the operation of the fuel fill door. PARTS INFORMATION Fuel fill door spring boot: Accord P/N 63910-SV4-999, H/C 4561817 Prelude P/N 63910-SR4-999, H/C 4561809 Fuel fill door shim: Civic P/N 90550-SR4-999, H/C 4825220 [NEW] WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. Operation number: 849102 Flat rate time: 0.3 hour Failed part: P/N 74494-SM4-010 H/C 3820594 Defect code: 032 Contention code: B01 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair Hood Latch Release Cable: Service and Repair ALIGNMENT: The hinges can be adjusted right and left as well as fore and aft by using the elongated holes. - Turn the edge cushions as necessary, to make the hood fit flush with the body at front and side edges. Adjust the hood latch to obtain the proper height at the forward edge. NOTE: Before pulling out the opener cable, tie a string to the cable so you can pull it back in later. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair > Page 8326 - Take care not to bend the opener cable. Installation is the reverse of the removal procedure. NOTE: Make sure the opener cable is routed and connected properly. - Adjust the hood alignment. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Technical Service Bulletins > Customer Interest for Trunk / Liftgate Latch: > 93002 > Nov > 94 > Body - Trunk Hard To Open With Key Trunk / Liftgate Latch: Customer Interest Body - Trunk Hard To Open With Key Bulletin No. 93-002 Issue Date NOV. 7, 1994 Model [NEW] 1992 - 95 CIVIC Applicable To See VEHICLES AFFECTED File Under BODY Civic Trunk Hard to Open With Key (Supersedes 93-002, dated January 15, 1993) SYMPTOM Excessive turning force is required to open the trunk with the key. PROBABLE CAUSE The trunk latch has improper clearance. VEHICLES AFFECTED [NEW] 4-door: 1992 - ALL 1993 - ALL 1994 DX, LX - Thru VIN 1HGEG8...RL023648 1995 DX, LX - Thru VIN JHMEG8...55007277 1995 EX - Thru VIN JHMEH9...SS003300 2-door: 1993 - ALL 1994 - Thru VIN 2HGEJ...RH518392 1994 DX - Thru VIN 1HGEJ2...RL010397 PARTS INFORMATION [NEW] Trunk Latch: P/N 74851-SR4-023, H/C 4585386 Striker Shims: 1.0 mm - P/N 83307-SD2-900, H/C 2321222 2.0 mm - P/N 83307-SD2-000, H/C 2321214 CORRECTIVE ACTION Replace the trunk latch with the part listed under PARTS INFORMATION. 1. Remove the three mounting screws from the trunk latch. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Technical Service Bulletins > Customer Interest for Trunk / Liftgate Latch: > 93002 > Nov > 94 > Body - Trunk Hard To Open With Key > Page 8336 2. Disconnect the latch rod, the opener cable, and the connector; then remove the trunk latch. 3. Reconnect the opener cable and the wire connector; then install the new trunk latch. Tighten the three mounting screws to 10 N-m (1.0 kg-m. 7.2 lb.ft.). 4. Connect the trunk latch rod to the new trunk latch. 5. Use the key to check the operation of the trunk lock. ^ If the trunk now opens easily with the key, the repair is complete. ^ If the trunk is still hard to open, continue to step 6. 6. Adjust the trunk lid edge cushions to get the trunk lid to sit flush with the body. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Technical Service Bulletins > Customer Interest for Trunk / Liftgate Latch: > 93002 > Nov > 94 > Body - Trunk Hard To Open With Key > Page 8337 7. Adjust the striker to align the trunk lid with the opening. Use shims as necessary. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. Operation number: 823109 [NEW] Flat rate time: 0.3 hour Failed part: P/N 74851-SR4-003 H/C 3890126 Defect code: 030 Contention code: B99 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Latch: > 93002 > Nov > 94 > Body - Trunk Hard To Open With Key Trunk / Liftgate Latch: All Technical Service Bulletins Body - Trunk Hard To Open With Key Bulletin No. 93-002 Issue Date NOV. 7, 1994 Model [NEW] 1992 - 95 CIVIC Applicable To See VEHICLES AFFECTED File Under BODY Civic Trunk Hard to Open With Key (Supersedes 93-002, dated January 15, 1993) SYMPTOM Excessive turning force is required to open the trunk with the key. PROBABLE CAUSE The trunk latch has improper clearance. VEHICLES AFFECTED [NEW] 4-door: 1992 - ALL 1993 - ALL 1994 DX, LX - Thru VIN 1HGEG8...RL023648 1995 DX, LX - Thru VIN JHMEG8...55007277 1995 EX - Thru VIN JHMEH9...SS003300 2-door: 1993 - ALL 1994 - Thru VIN 2HGEJ...RH518392 1994 DX - Thru VIN 1HGEJ2...RL010397 PARTS INFORMATION [NEW] Trunk Latch: P/N 74851-SR4-023, H/C 4585386 Striker Shims: 1.0 mm - P/N 83307-SD2-900, H/C 2321222 2.0 mm - P/N 83307-SD2-000, H/C 2321214 CORRECTIVE ACTION Replace the trunk latch with the part listed under PARTS INFORMATION. 1. Remove the three mounting screws from the trunk latch. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Latch: > 93002 > Nov > 94 > Body - Trunk Hard To Open With Key > Page 8343 2. Disconnect the latch rod, the opener cable, and the connector; then remove the trunk latch. 3. Reconnect the opener cable and the wire connector; then install the new trunk latch. Tighten the three mounting screws to 10 N-m (1.0 kg-m. 7.2 lb.ft.). 4. Connect the trunk latch rod to the new trunk latch. 5. Use the key to check the operation of the trunk lock. ^ If the trunk now opens easily with the key, the repair is complete. ^ If the trunk is still hard to open, continue to step 6. 6. Adjust the trunk lid edge cushions to get the trunk lid to sit flush with the body. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Latch: > 93002 > Nov > 94 > Body - Trunk Hard To Open With Key > Page 8344 7. Adjust the striker to align the trunk lid with the opening. Use shims as necessary. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. Operation number: 823109 [NEW] Flat rate time: 0.3 hour Failed part: P/N 74851-SR4-003 H/C 3890126 Defect code: 030 Contention code: B99 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Locations > Trunk Latch Switch Trunk / Liftgate Latch: Locations Trunk Latch Switch Center Rear Of Trunk Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Locations > Trunk Latch Switch > Page 8347 Trunk / Liftgate Latch: Locations Tailgate Latch Switch Left Side Of Tailgate (Right Similar) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Locations > Trunk Latch Switch > Page 8348 Trunk / Liftgate Latch: Locations Hatch Latch Switch Center Of Tailgate Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Exterior Moulding / Trim > System Information > Technical Service Bulletins > Body - Chrome/Stainless Trim Staining Information Exterior Moulding / Trim: Technical Service Bulletins Body - Chrome/Stainless Trim Staining Information Getting Rid of Stains on Chrome or Stainless Steel Unsightly stains on chrome or stainless steel trim around the door glass no longer means trim replacement. A good-quality chrome or aluminum polish, some careful masking to protect rubber molding and painted surfaces, and a little bit of elbow grease, can work wonders to get back that showroom shine. A couple of good brands to try are Mothers PowerMetal(TM), or Meguiars All Metal Polish or NXT Generation(TM) All Metal Polish. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Specifications Air Bag(s) Arming and Disarming: Specifications Component .......................................................................................................................................... ....................................................... Torque/Ft. Lbs. Dash Sensor Mounting Bolts .............................. .............................................................................................................................................................. .. 16 Driver Side Air Bag Assembly To Steering Wheel Bolts ................................................................................................................................................. 7.2 Passenger Side Air Bag Mounting Nuts & Bolts .................................................................................. ............................................................................. 7.2 SRS Unit Mounting Bolts ................................. .............................................................................................................................................................. .. 7.2 Steering Wheel To Column Steering Shaft Nut .......................................................................... ....................................................................................... 36 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Specifications > Page 8358 Air Bag(s) Arming and Disarming: Service Precautions 1. On models with 3-P SRS connectors, install red short connectors on air bags prior to disconnecting any part of SRS wiring harness. 2-P SRS connectors automatically short when disconnected. 2. Always use test harnesses. Do not use test probes directly on component connector pins or wires. 3. When connecting any test harnesses, push connectors straight in until secure. Do not bend connector pins. 4. Always keep red short connector on air bag connector when harness is disconnected. 5. Always store air bag assembly with pad surface facing upward. 6. Do not attempt to disassemble air bag assembly. 7. An air bag that has been deployed cannot be repaired or reused. 8. Keep air bag assembly free of oil and grease. 9. Do not expose air bag assembly to temperatures above 212°F. 10. Do not use SRS components from another vehicle. Always install new replacement components. 11. Do not paint air bag assembly to correct cosmetic flaws. It must be replaced. 12. Inspect all components prior to installation. Do not install any that appear to have been improperly handled or stored or that show any signs of damage. 13. When repairing vehicle, system should be disarmed as outlined under Technician Safety Information. 14. When performing service procedures, do not expose sensors or wiring or other SRS components to heat guns, welding or spray guns. 15. SRS wiring should not be spliced, soldered or repaired. 16. Use only special digital multimeter tool No. KS-AHM-32-003, or equivalent, digital multimeter with 0.0 mA or smaller output when switched to lowest ohmmeter range to inspect system. Analog or testers with higher outputs can damage circuits or cause accidental air bag deployment and, if equipped, seat belt pretensioner activation. 17. Do not bump SRS unit whenever ignition is turned On, or has been Off for less than three minutes. Unwanted deployment could result. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Specifications > Page 8359 Air Bag(s) Arming and Disarming: Service and Repair The Supplemental Restraint System (SRS) must be disarmed prior to disconnecting any electrical connectors or servicing any system components or items located near SRS electrical connectors. SRS electrical wiring can be identified by its yellow outer protective coating. To disarm the SRS, proceed as follows: 1. Obtain five-digit radio theft protection code number. 2. Disconnect battery ground cable, then the positive cable. Fig. 1 Driver Air Bag Disarming 3. After disconnecting cables, wait at least three minutes with ignition turned Off before disconnecting any SRS electrical connectors. This will allow air bag system back-up circuit capacitor to discharge. 4. Remove steering wheel access panel and disconnect electrical connector located between air bag and cable reel, Fig. 1 5. Remove glove compartment and access panel. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Specifications > Page 8360 Fig. 4 Passenger Air Bag Disarming 6. Disconnect front passenger air bag 3-P connector from SRS main harness and connect red short connector, Fig. 4. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Specifications > Page 8361 Fig. 12 Fuse Panel/SRS Connector 7. Using thin blade screwdriver, lift SRS to under-instrument panel fuse connector lid, Fig. 12, then press tab down and slide connector out. 8. Reverse procedure to reactivate system, noting following: a. Slide harness electrical connector onto fuse panel connections until it clicks, then close connector lid. b. Ensure all red short connectors have been removed and placed in their holders. c. Prior to connecting battery ground and positive cables, ensure all supplemental restraint system electrical connectors have been properly connected. d. After battery cables have been connected, turn ignition switch to On position. SRS indicator lamp should light for approximately six seconds. If lamp does not light or remains on longer than six seconds, A SYSTEM MALFUNCTION IS INDICATED. Refer to Testing and Inspection / Procedures See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview e. Turn radio control to On. When word Code appears on display panel, enter five-digit theft protection code number. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Technical Service Bulletins > Customer Interest for Drink Holders: > 92048 > Apr > 95 > Interior - Cup Holder Difficult to Open/Opens by Itself Drink Holders: Customer Interest Interior - Cup Holder Difficult to Open/Opens by Itself BULLETIN NO. 92-048 ISSUE DATE APR 24, 1995 MODEL 1992-95 CIVIC [NEW] APPLICABLE TO ALL FILE UNDER BODY Cup Holder Difficult to Open or Opens by Itself (Supersedes 92-048, Cup Holder Opens by Itself, dated April 16, 1993) SYMPTOM The cup holder is difficult to open or it opens by itself when the car is driven over rough roads. PROBABLE CAUSE Liquid has spilled inside the cup holder, or the latch engages improperly. CORRECTIVE ACTION inspect and clean the inside of the cup holder, check the latch operation, and adjust the latch. Install a new latch (see PARTS INFORMATION), if needed. 1. Remove the center console. 2. Remove the cup holder from the center console (four screws). 3. Open the cup holder, and check for stickiness on the inside. If necessary, thoroughly clean the inside of the cup holder and its components with soap and water. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Technical Service Bulletins > Customer Interest for Drink Holders: > 92048 > Apr > 95 > Interior - Cup Holder Difficult to Open/Opens by Itself > Page 8370 4. Check the operation of the latch by depressing and releasing it several times with your finger. If the latch sticks, replace it with a new one (see PARTS INFORMATION). 5. Turn the cup holder upside down, and remove the latch (one screw). 6. Scribe a mark on the latch mounting boss, 3 mm from the base of the boss. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Technical Service Bulletins > Customer Interest for Drink Holders: > 92048 > Apr > 95 > Interior - Cup Holder Difficult to Open/Opens by Itself > Page 8371 7. Using a small flat file, file down the mounting boss at an angle to the scribe mark. 8. Reinstall the latch, and apply thread lock to the mounting screw. Tighten the screw until the latch ear is flush with the mounting boss. 9. Open and close the cup holder to check for proper operation. 10. Reinstall the cup holder on the center console, then reinstall the center console in the car. PARTS INFORMATION Latch assembly: [NEW] P/N 8341 8-SR3-000, H/C 4447058 WARRANTY CLAIM INFORMATION IN WARRANTY: The normal warranty applies. OUT OF WARRANTY: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. Operation number: 044320 [NEW] Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Technical Service Bulletins > Customer Interest for Drink Holders: > 92048 > Apr > 95 > Interior - Cup Holder Difficult to Open/Opens by Itself > Page 8372 Flat rate time: 0.5 hour [NEW] Failed part: P/N 83416-SR3-003ZC [NEW] H/C 3896214 [NEW] Defect code: 031 Contention code: B99 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drink Holders: > 92048 > Apr > 95 > Interior - Cup Holder Difficult to Open/Opens by Itself Drink Holders: All Technical Service Bulletins Interior - Cup Holder Difficult to Open/Opens by Itself BULLETIN NO. 92-048 ISSUE DATE APR 24, 1995 MODEL 1992-95 CIVIC [NEW] APPLICABLE TO ALL FILE UNDER BODY Cup Holder Difficult to Open or Opens by Itself (Supersedes 92-048, Cup Holder Opens by Itself, dated April 16, 1993) SYMPTOM The cup holder is difficult to open or it opens by itself when the car is driven over rough roads. PROBABLE CAUSE Liquid has spilled inside the cup holder, or the latch engages improperly. CORRECTIVE ACTION inspect and clean the inside of the cup holder, check the latch operation, and adjust the latch. Install a new latch (see PARTS INFORMATION), if needed. 1. Remove the center console. 2. Remove the cup holder from the center console (four screws). 3. Open the cup holder, and check for stickiness on the inside. If necessary, thoroughly clean the inside of the cup holder and its components with soap and water. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drink Holders: > 92048 > Apr > 95 > Interior - Cup Holder Difficult to Open/Opens by Itself > Page 8378 4. Check the operation of the latch by depressing and releasing it several times with your finger. If the latch sticks, replace it with a new one (see PARTS INFORMATION). 5. Turn the cup holder upside down, and remove the latch (one screw). 6. Scribe a mark on the latch mounting boss, 3 mm from the base of the boss. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drink Holders: > 92048 > Apr > 95 > Interior - Cup Holder Difficult to Open/Opens by Itself > Page 8379 7. Using a small flat file, file down the mounting boss at an angle to the scribe mark. 8. Reinstall the latch, and apply thread lock to the mounting screw. Tighten the screw until the latch ear is flush with the mounting boss. 9. Open and close the cup holder to check for proper operation. 10. Reinstall the cup holder on the center console, then reinstall the center console in the car. PARTS INFORMATION Latch assembly: [NEW] P/N 8341 8-SR3-000, H/C 4447058 WARRANTY CLAIM INFORMATION IN WARRANTY: The normal warranty applies. OUT OF WARRANTY: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. Operation number: 044320 [NEW] Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drink Holders: > 92048 > Apr > 95 > Interior - Cup Holder Difficult to Open/Opens by Itself > Page 8380 Flat rate time: 0.5 hour [NEW] Failed part: P/N 83416-SR3-003ZC [NEW] H/C 3896214 [NEW] Defect code: 031 Contention code: B99 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair Headliner: Service and Repair Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 8384 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch Key: Technical Service Bulletins Starting System - Unable To Key In Ignition Switch Can't Turn Ignition Switch? Check for Locked Steering Got a service customer complaining he or she can't turn the ignition switch to start the engine? The reason could just be the steering column lock pin is engaged with the front wheels turned. Here's what typically happens: Some folks use the steering wheel to help support themselves while climbing in or out of the vehicle. This is very common among elderly or disabled drivers. Doing this turns the front wheels, which twists the tires against the ground. The twisted tires apply torque to the steering column. With the ignition switch in LOCK (0), the steering column lock pin is engaged. But the applied torque on the steering column binds the lock pin, making it tough to turn the ignition switch. The ignition switch won't turn to ON (II) if the lock pin isn't disengaged from the steering column. Tell your customer there's nothing wrong with the ignition switch itself. All he or she needs to do is turn the steering wheel from side to side while turning the switch. This usually releases the lock pin so the engine can be started. In some cases, though, your customer may need to give a good tug on the wheel. This could easily happen when parking on a hill and the wheels are turned sharply before the engine is shut off. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information Technical Service Bulletin # 98-011 Date: 040220 Keyless Entry - Remote Transmitter Information 98-011 February 20, 2004 Applies To: ALL Keyless Remote Transmitter Information (Supersedes 98-011, dated February 6, 2003) Updated information is shown by asterisks and a black bar. This service bulletin gives you information about keyless remote transmitters for most Honda vehicles. Each procedure describes transmitter programming (if applicable), transmitter ordering, and transmitter batteries. A remote transmitter quick reference guide is shown below. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8395 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8396 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8397 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8398 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8399 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8400 Remote Transmitter Quick Reference Guide 90-93 Accord, 92-93 Civic & Prelude, 93 Del SOL 1990-93 Accord (2-door and 4-door) with dealer-installed security system 1992-93 Civic with dealer-installed security system 1993 del Sol with dealer-installed security system 1992-93 Prelude with dealer-installed security system Programming the Transmitter NOTE: Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8401 This system uses ROM chips that match the transmitter to the security system control unit. When replacing a lost or stolen transmitter, you need to use the three ROM chips (provided with the new transmitter) to match the old transmitter with the new transmitter and the control unit. 1. Remove the rear cover from the old transmitter and the new one. 2. Remove the ROM chip from the old transmitter by sliding its socket holder toward the ROM chip. 3. Insert a new ROM chip into the socket holder, then slide the socket holder toward the socket to lock the chip in place. 4. Repeat step 3 to install a ROM chip into the new transmitter. 5. Reinstall the rear covers on the transmitters. 6. Remove the security system control unit from under the driver's seat. 7. Open the access cover on the control unit, and replace the ROM chip. (Use the same procedure as in steps 2 and 3.) 8. Press the reset button next to the ROM chip. 9. Close the access cover, and reinstall the control unit. If you are replacing a damaged transmitter, don't replace the ROM chips in the transmitters and the control unit; just remove the chip from the old transmitter and install it in the new one. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. If your customer wants to add a third transmitter to the system, you need to order a four ROM chip set directly from Alpine Electronics of America. The Alpine part number for the four ROM chip set is 5319. This ROM chip set does not come with a transmitter. Order the additional transmitter from American Honda. If you have questions about how to order a four ROM chip set, call Alpine's parts department at (800) 421-2284, extension 8885. Batteries for the Transmitter Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8402 The battery number is CR2025. Each transmitter uses one battery. 94-95 Accord, Civic, Del SOL, Prelude & 95 Odyssey 1994-95 Accord with dealer-installed security system 1994-95 Civic with dealer-installed security system 1994-95 del Sol with dealer-installed security system 1994-95 Prelude with dealer-installed security system 1995 Odyssey with dealer-installed security system Programming the Transmitter NOTES: ^ The system uses a stacking-type memory that accepts up to four transmitters. If you program a fifth transmitter, the system's memory for the first transmitter is pushed out, and it will no longer work. ^ To clear a lost or stolen transmitter from the system's memory, program a transmitter four times. This will remove the missing transmitter from memory, since only four transmitter codes can be accepted. ^ Another way to clear a lost or stolen transmitter is to erase all transmitter codes, and then reprogram them. To do this, refer to the security system owner's manual. 1. Turn the ignition switch to ON (II). 2. Press and hold the Valet-Disarm button on the dashboard lower cover. (Continue to hold the button during this procedure, or programming will be cancelled.) The LED on the upper steering column cover flashes when the system is in programming mode. 3. Press the top button on the transmitter. Check that the parking lights flash to confirm that the transmitter's code was accepted. 4. Press the top button on each of the remaining transmitters. Check that the parking lights flash after each transmitter code is accepted. 5. Release the Valet-Disarm button to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 96-98 Civic EX & Except EX, Civic 1996-98 Civic EX with factory-installed keyless entry system 1996-98 Civic (except EX) with dealer-installed keyless entry system 1996-98 Civic with dealer-installed security system Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8403 Programming the Transmitter NOTES: ^ The system accepts up to four transmitters. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all the transmitters once you're in the programming mode. 1. Turn the ignition switch to ON (II). 2. Press and hold the Valet-Disarm button on the radio (between the AM/FM and CD/TAPE buttons) to enter the programming mode. (Continue to hold the button during this procedure, or programming will be cancelled.) Check that the power door locks cycle to confirm that you're in the programming mode. 3. Within 5 seconds, press the "Lock" or "Unlock" button on the transmitter. Check that the power door locks cycle to confirm that the code was accepted. 4. Within 10 seconds, press the "Lock" or "Unlock" button on each of the remaining transmitters. 5. After all the transmitters have been programmed, release the Valet-Disarm button to exit programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 99-04 Civic, 03-04 Accord, Element, Pilot 1999-00 Civic Value Package with factory-installed keyless entry system 1999-04 Civic EX with factory-installed keyless entry system or dealer-installed security system *1999-03 Civic (except EX) with dealer-installed keyless entry system or security system 2002-04 Civic Si with factory-installed keyless entry system or dealer-installed security system 2003-04 Civic Hybrid with factory-installed keyless entry system or dealer-installed security system 2004 Civic (except LX & EX) with dealer-installed keyless entry system or security system 2004 Civic LX with factory-installed keyless entry system or dealer-installed security system Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8404 2003-04 Accord DX with dealer-installed security system 2003-04 Element with dealer-installed keyless entry system or security system 2004 Element EX with factory-installed keyless entry system or dealer-installed security system 2003-04 Pilot EX models with factory-installed security system* Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 91-93 Accord 5-D00R EX Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8405 1991-93 Accord 5-door EX with factory-installed keyless entry or dealer-installed security system Programming the Transmitter The transmitter is not programmable. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. To order a transmitter, you need the vehicle's VIN, the code number from the power door lock control unit, and the ignition key code number. The power door lock code number is a five-digit number etched into the plastic case of the control unit (mounted under the driver's seat). The ignition key code number is a four-digit number stamped on the metal shank of all five original keys delivered with the car. Replacement transmitters are manufactured to match the code of the keyless entry system. The new ignition key is cut to match the vehicle's ignition switch, front door locks, tailgate lock, and glove compartment lock. To order this transmitter, use the controlled parts ordering screen on the iN system. The transmitters are manufactured in Japan; delivery takes 4 to 6 weeks. Batteries for the Transmitter The battery is not replaceable. 91-93 Accord 5-Door LX 1991-93 Accord 5-door LX with dealer-installed security system Programming the Transmitter This transmitter is not programmable. Ordering a Transmitter Transmitters can be ordered directly from Kenwood USA only by authorized Honda dealers. Send a completed order form (copy it from the Accessory Replacement Parts section of the Dealer Parts Price List) along with a dealer check for $30.00 (payable to Kenwood U.S.A. Corp.) to this address: Kenwood Service Corp. P.O. Box 22745 Long Beach, CA 90501-5745 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8406 On the order form, you must include the serial number of the keyless control unit or the number from one of the original transmitters. If you need a transmitter shipped overnight, fill out the order form, then call Kenwood at (500) 552-4690, or fax them at (310) 595-1029 (weekdays from 5:30A.M. thru 4:00 P.M. Pacific time). You will need to give the information on the order form to the Kenwood representative. The transmitter will be sent to your dealership COD. Additional shipping and handling charges will be applied to the order. Batteries for the Transmitter The battery number is CR1220. Each transmitter uses two batteries. 94-97 Accord 5-Door EX, 95-98 Odyssey EX 1994-97 Accord 5-door EX with factory-installed keyless entry system 1995-98 Odyssey EX with factory-installed keyless entry system Programming the Transmitter NOTE: ^ The system accepts up to two transmitters. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. 1. Open the driver's door. 2. Push the driver's power door lock switch to the unlock position and hold it. (Continue to hold the switch during this procedure.) 3. Insert the key into the ignition switch, then remove it. Repeat this four more times (five times total) within 10 seconds. (You must complete steps 3 and 4 within 10 seconds or the system will exit the programming mode.) 4. Insert the key into the ignition switch. After you insert the key, make sure the power door locks cycle to confirm that the system is in the programming mode. 5. Press the "LOCK" or "UNLOCK" button on the transmitter. All the power door locks (except the driver's door) should cycle to confirm that the system accepted the transmitter's code. 6. To program a second transmitter, press its "LOCK" or "UNLOCK" button within 10 seconds of programming the first transmitter. 7. Release the master power door lock switch to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2016. Each transmitter uses two batteries. 96-04 Accord, CRV, DelSOL, Ody., Prelude, S2000, Insight, Pilot 1996-02 Accord with dealer-installed security system 1998-02 Accord DX & LX with dealer-installed keyless entry system Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8407 1997-01 CR-V with dealer-installed security system 1996-97 del Sol with dealer-installed security system 1996-98 Odyssey with dealer-installed security system *1999-04 Odyssey LX with dealer-installed keyless entry system or security system* 1996-01 Prelude with dealer-installed security system *2000-04 S2000 with dealer-installed security system 2000-04 Insight with dealer-installed security system 2003-04 Pilot LX with dealer-installed keyless entry system or security system* Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8408 1997 Accord SE With Factory-Installed Security System 1997 Accord SE with factory-installed security system Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 5. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 98-02 Accord EX & 00-02 Accord SE 1998-02 Accord EX with factory-installed security system 2000 and 2002 Accord SE with factory-installed security system Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8409 (Not interchangeable with CR-V and S2000 remote transmitter) Transmitter Identification The transmitter for the 1995-99 Accord and the 2000-02 Accord look identical, but they are not interchangeable. The 1995-99 transmitter works the doors of a 2000-02 Accord, but it does not open the trunk. If you are not sure which transmitter you have, press and hold the trunk release button while looking at the LED. The LED on the 1995-99 transmitter comes on in about 1.1 seconds. The LED on the 2000-02 transmitter comes on in about 0.5 second. Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 03-04 Accord LX and EX 2003-04 Accord LX and EX with factory-installed keyless entry system Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8410 Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR1616. Each transmitter uses one battery. 97-04 CR-V & 00-04 S2000 *1997-04 CR-V LX with dealer-installed keyless entry system 1998-04 CR-V EX with factory-installed keyless entry system 2000-01 CR-V SE with factory-installed keyless entry system 2000-04 S2000 with factory-installed keyless entry system 2002-04 CR-V with dealer-installed security system* Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8411 Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete each step within 4 seconds of the previous step to keep the system from exiting the programming mode. Program the transmitters within 10 seconds. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 99-04 Odyssey EX 1999-00 Odyssey EX with factory-installed keyless entry system or dealer-installed security system *2001-04 Odyssey EX models with factory- installed security system* *Transmitter Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8412 The 1999-00 transmitter is not interchangeable with the 2001-04 transmitter. To tell them apart, look at the FCC ID on the back. 1999-00 - FCC ID: E4EG8DN 2001-04 - FCC ID: OUCG8D-440H-A* Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 99-01 Prelude With Factory-Installed Keyless Entry System 1999-01 Prelude with factory-installed keyless entry system Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8413 Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 88-91 Prelude With Dealer-Installed Security System 1988-91 Prelude with dealer-installed security system Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8414 Programming the Transmitter This transmitter is not programmable. Ordering a Transmitter This transmitter is no longer available. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses two batteries. 97-99 EV Plus With Factory-Installed Security System 1997-99 EV Plus with factory-installed security system Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 5. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only through Tech Line. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 00-04 Insight With Factory-Installed Keyless Entry System 2000-04 Insight with factory-installed keyless entry system Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8415 Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 94-95 Passport (Except 1995-1/2) 1994-95 Passport (except 19951A) with dealer-installed security system NOTES: ^ The system uses a stacking-type memory that accepts up to four transmitters. If you program a fifth transmitter, the memory for the first transmitter is pushed out, and it will no longer work. ^ To clear a lost or stolen transmitter from the system's memory, program a transmitter four times. This will remove the missing transmitter from memory, since only four transmitters can be accepted. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8416 Programming the Transmitter 1. Locate the security system control unit under the driver's seat. 2. Rub your finger over the label on the top of the control unit until you find the depression. Once you find it, push your finger through the label to expose the hole underneath. Inside the hole is a square, yellow button; this is the programming button. 3. Turn the ignition switch to ON, then turn it to LOCK. 4. Press and hold the programming button. Check that the security siren emits four separate chirps followed by a five-chirp burst. This confirms that the system is in programming mode. The siren then emits prompting chirps at 3-second intervals. 5. Release the programming button. 6. After a prompting chirp, press the "LOCK" button on the transmitter. Verify that the siren emits a confirmation chirp to confirm that the transmitter's code was accepted by the control unit. If you wait more than 30 seconds after the prompting chirp before programming a transmitter, or wait more than 30 seconds between programming transmitters, the siren emits three chirps and the system exits the programming mode. 7. To program additional transmitters, wait for another prompting chirp, then press the "LOCK" button. (You can program up to four transmitters per vehicle.) 8. To exit the programming mode, turn the ignition switch to ON, then turn it to LOCK. 9. Test all the transmitters. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is 23-144 (Radio Shack), A-23 (Eveready), or MS-21/MN-21 (Duracell). Each transmitter uses one battery. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8417 96-97 Passport With Dealer-Installed Security System 1996-97 Passport with dealer-installed security system NOTES: ^ The system uses a stacking-type memory that accepts up to two transmitters. If you program a third transmitter, the memory for the first transmitter is pushed out, and it will no longer work. ^ To clear a lost or stolen transmitter from the system's memory, program a transmitter two times. This will remove the missing transmitter from memory, since only two transmitter codes can be accepted. ^ Another way to clear a lost or stolen transmitter is to erase all transmitter codes and then reprogram them. To do this, refer to the security system owner's manual. Programming the Transmitter 1. Move the driver's seat forward. Locate the security system control unit mounted on the floor underneath the seat. 2. Turn the ignition switch to ON. 3. Use a pen or pencil to press and hold the green programming button on the side of the control unit. When the security system LED on the instrument panel comes on, release the programming button. (Steps 3 and 4 must be done within 5 seconds of each other.) 4. Press and release the top button on the transmitter. Verify that the LED goes out, the siren chirps once, and the front sidemarker lights flash to confirm that the transmitter's code was accepted by the control unit. 5. Turn the ignition switch to LOCK, then to ON. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8418 6. Press and hold the green programming button on the side of the control unit until the LED on the instrument panel begins to flash, then release the button. (Steps 6 and 7 must be done within 5 seconds of each other.) 7. Press and release the bottom button on the transmitter. Verify that the LED goes out, the siren chirps twice, and the front sidemarker lights flash twice to confirm that the transmitter's code was accepted by the control unit. 8. Turn the ignition switch to LOCK. Test the transmitter you just programmed. If it doesn't work repeat steps 2 thru 7. 9. If you have another transmitter to program, repeat steps 2 thru 7. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 98-02 Passport With Factory-Installed Security System 1998-02 Passport with factory-installed security system Programming the Transmitter To program the transmitters, use one of these two procedures: ^ Procedure One cancels all learned transmitter codes and adds one new transmitter. None of the previously programmed transmitters will work. Use this programming procedure only if all transmitters were lost or stolen, or if a new control unit has been installed. ^ Procedure Two adds additional transmitters without cancelling any of the previously learned codes. The system will accept up to four transmitters. Procedure One (cancels all codes, adds one new transmitter) 1. Open the driver's door. 2. Turn the ignition switch to the ACC position and then to the LOCK position three times. (This step must be completed within 10 seconds, or the system will not enter the programming mode.) 3. Within 10 seconds, close and open the door two times. 4. Turn the ignition switch to the ACC position and then to the LOCK position five times. Close and open the door. (Complete this process within 10 seconds.) Verify that the power door locks cycle once to confirm that the system is in programming mode. 5. Within 20 seconds, press the "LOCK" button on the transmitter you are programming. Verify that the door locks cycle once. 6. Within 20 seconds, press the "UNLOCK" button on the transmitter. Verify that the door locks cycle once to confirm that the system has accepted the transmitter's code. Procedure Two (adds transmitters) 1. Open the driver's door. 2. Turn the ignition switch to the ACC position and then to the LOCK position three times. (This step must be completed within 10 seconds, or the Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8419 system will not enter the programming mode.) 3. Within 10 seconds, close and open the door two times. 4. Turn the ignition switch to the ACC position and then to the LOCK position three times. Close and open the door. (Complete this process within 10 seconds.) Verify that the power door locks cycle once to confirm that the system is in programming mode. 5. Within 20 seconds, press the "LOCK" button on the transmitter you are programming. Verify that the door locks cycle once. 6. Within 20 seconds, press the "UNLOCK" button on the transmitter. Verify that the door locks cycle once to confirm that the system has accepted the transmitter's code. Turning the Audible Chirp On/Off (1998-99 only) NOTE: On '00-02 Passports, the audible chirp sounds only when you push the LOCK button on the transmitter a second time. 1. Open the driver's door, then insert the key in the driver's door lock. 2. Turn the key to the "LOCK" position, then to the "UNLOCK" position. Repeat this two more times. (Complete this procedure within 10 seconds.) 3. Within 10 seconds, close and open the door two times. 4. Within 10 seconds, turn the key to the "LOCK" position, and then to the "UNLOCK" position, three times. Close and open the door once. Verify that the power door locks cycle once to confirm that the chirp has been turned on/off. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2016. Each transmitter uses two batteries. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8420 Technical Service Bulletin # 96-046 Date: 961021 Keyless Entry - Transmitter Programming Information Bulletin No. 96-046 Issue Date OCT 21, 1996 Model ALL Applicable To Refer to the list below File Under ACCESSORIES Keyless Remote Transmitter Information This Service Bulletin gives you information about keyless remote transmitters for most Honda vehicles. Each procedure describes transmitter programming (if applicable), transmitter ordering*, and transmitter batteries. A transmitter quick reference guide is included. Use this index to find the information for the vehicle you are working on. Vehicle: Procedure Number: Civic 1992-93 2 1994-95 5 1996-97 8 del Sol 1993 2 1994-95 5 1996-97 7 Accord 1990-93 (except Wagon) 2 1991-93 EX Wagon 3 1991-93 LX Wagon 4 1994-95 (with optional security system) 5 1994-97 EX Wagon 6 1996-97 (with optional security system) 7 Prelude 1988-91 1 1992-93 (with optional security system) 2 1994-95 (with optional security system) 5 1996-97 (with optional security system) 7 Odyssey 1995 (with optional security system) 5 1995-97 EX 6 1996-97 (with optional security system) 7 Passport 1994-95 (with optional security system, not applicable to 1995.5 model) 9 1996-97 (with optional security system) 10 *Transmitter prices are subject to change without notice. PARTS INFORMATION Transmitter ordering information and battery part numbers are in each transmitter section. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8421 WARRANTY CLAIM INFORMATION None. This Service Bulletin is for information only. TRANSMITTER QUICK REFERENCE GUIDE Procedure 1 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8422 Programming the Transmitter This transmitter is not programmable. Ordering the Transmitter Transmitters can be ordered directly from Alpine of America by authorized Honda Dealers only. Send a completed order form (found in Parts Information Bulletin A91 -0031) along with a dealer check for $59.00 (payable to Alpine of America), to this address: Honda/Alpine V.S.S. P.O. Box 2859 Torrance, CA 90509 Batteries for the Transmitter The battery number is CR2025. Each transmitter uses two batteries. Procedure 2 Programming the Transmitter NOTE: This system uses ROM chips that match the transmitter to the security system control unit. When replacing a lost or stolen transmitter, you need to use the three ROM chips (provided with the new transmitter) to match the old transmitter with the new transmitter and the control unit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8423 1. Remove the rear cover from the old transmitter and the new one. 2. Remove the ROM chip from the old transmitter by sliding its socket holder toward the ROM chip. 3. Insert a new ROM chip into the socket holder, then slide the socket holder toward the socket to lock the chip into place. 4. Repeat step 3 to install a ROM chip into the new transmitter. 5. Reinstall the rear covers on the transmitters. 6. Remove the security system control unit from under the driver's seat. 7. Open the access cover on the control unit, and replace the ROM chip. (Use the same procedure as in steps 2 and 3.) 8. Close the access cover, and reinstall the control unit. If you are replacing a damaged transmitter, don't replace the ROM chips in the transmitters and the control unit; just remove the chip from the old transmitter, and install it in the new one. Ordering the Transmitter Transmitters can be ordered only by authorized Honda Dealers. Order them from American Honda using normal parts ordering procedures. If your customer wants to add a third transmitter to the system, you need to order a four ROM chip set directly from Alpine Electronics of America. The Alpine part number for the four ROM chip set is 8319. For each set ordered, send a dealer check for $24.00 (payable to Alpine of America), to this address: Alpine Electronics of America 19145 Gramercy Place Torrance, CA 90501 Attention: Al Sula (Parts) Alpine's ROM chip set does not come with a transmitter. Additional transmitters can be ordered from American Honda using normal parts ordering procedures. If you have questions on how to order the four ROM chip set, call Alpine's Parts Department at (800) 421-2284, extension 8885. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8424 Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. Procedure 3 Programming the Transmitter This transmitter is not programmable. Ordering the Transmitter Transmitters can be ordered only by authorized Honda Dealers. To order a transmitter, you need the vehicle's VIN, the code number from the power door lock control unit, and the ignition key code number. The power door lock code number is a five-digit number etched into the plastic case of the control unit (mounted under the driver's seat). The ignition key code number is a four-digit number stamped on the metal shank of all five original keys delivered with the car. Replacement transmitters are manufactured to match the code of the keyless entry system. The new ignition key is cut to match the vehicle's ignition switch, front door locks, tailgate lock, and glove compartment lock. To order this transmitter, use the controlled parts ordering screen on the HONDANET 2000 system. The transmitters are manufactured in Japan; delivery takes 4 to 6 weeks. Batteries for the Transmitter The battery is not replaceable. Procedure 4 Programming the Transmitter Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8425 This transmitter is not programmable. Ordering the Transmitter Transmitters can be ordered directly from Kenwood USA by authorized Honda Dealers only. Send a completed order form,* (copy it from the Accessory Replacement Parts section of the Dealer Parts Price List) along with a dealer check for $30.00 (payable to Kenwood U.S.A. Corp.), to this address: Kenwood Service Corp. P.O. Box 22745 Long Beach, CA 90801-5745 If you need a transmitter shipped overnight, fill out the order form, then call Kenwood at (800)852-4690, or Fax them at (310) 898-1029 (weekdays, from 8:30 A.M. thru 4:00 PM., PST). You will need to give the information on the order form to the Kenwood representative. The transmitter will be sent to your Dealership C.O.D. Additional shipping and handling charges will be applied to the order. Batteries for the Transmitter The battery number is CR1220. Each transmitter uses two batteries. *On the order form, you must include the serial number of the keyless control unit or the number from one of the original transmitters. Procedure 5 Programming the Transmitter NOTES: ^ The system uses a stacking-type memory that accepts up to four transmitters. If you program a fifth transmitter, the system's memory for the first transmitter is pushed out, and it will no longer work. ^ To clear a lost or stolen transmitter from the system's memory, program a transmitter four times. This will remove the missing transmitter from memory, since only four transmitter codes can be accepted. ^ Another way to clear a lost or stolen transmitter is to erase all transmitter codes and then reprogram them. To do this, refer to the security system owner's manual. 1. Turn the ignition switch ON (II). 2. Press and hold the Valet-Disarm button on the dashboard lower cover. (Continue to hold the button during the procedure, or programming will be cancelled.) The LED on the upper steering wheel cover flashes when the system is in the programming mode. 3. Press the top button on the transmitter. The parking lights flash to confirm that the transmitter's code was accepted. 4. Press the top button on each of the remaining transmitters. The parking lights flash after each transmitter code is accepted. 5. Release the Valet-Disarm button to exit the programming mode. Ordering the Transmitter Transmitters can be ordered only by authorized Honda Dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8426 The battery number is CR2025. Each transmitter uses one battery. Procedure 6 Programming the Transmitter NOTE: Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all the transmitters once you are in the programming mode. 1. Open the driver's door. 2. Press and hold the driver's door master power door lock switch up in the unlock position. (Continue to hold the switch during this procedure.) 3. Insert the key in the ignition switch and remove it. Repeat this four more times within 10 seconds, then leave the key in the switch. Check that the power door locks cycle to confirm that the system is in the programming mode. (This step must be completed within 10 seconds, or the system will exit the programming mode.) 4. Press the "LOCK" or "UNLOCK" button on the transmitter. Check that all power door locks (except the driver's) cycle to confirm that the transmitter's code was accepted by the system. 5. To program a second transmitter, press its "LOCK" or UNLOCK" button within 10 seconds of programming the first transmitter. (You can program two transmitters per vehicle.) 6. Release the master power door lock switch to exit the programming mode. Ordering the Transmitter Transmitters can be ordered only by authorized Honda Dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2016. Each transmitter uses two batteries. Procedure 7 Programming the Transmitter Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8427 NOTES: ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all the transmitters once you're in the programming mode. ^ To keep the system from exiting the programming mode, complete each step within 5 seconds of the previous step, and program the transmitters within 10 seconds of each other. 1. Turn the ignition switch ON (II). 2. Press the "LOCK" or "UNLOCK" button on one of the transmitters. (A non-programmed transmitter can be used for this step.) 3. Turn the ignition switch OFF (0). 4. Repeat steps 1, 2, and 3 two more times with the transmitter used in step 2. 5. Turn the ignition switch ON (II). 6. Press the "LOCK" or "UNLOCK" button on the same transmitter. Check that the power door locks cycle to confirm that you're in the programming mode. 7. Press the "LOCK" or "UNLOCK" button on each transmitter. (You can program up to four transmitters per vehicle) Check that the power door locks cycle after you push each transmitter button, confirming that the system has accepted the transmitter's code. Ordering the Transmitter Transmitters can be ordered only by authorized Honda Dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. Procedure 8 Programming the Transmitter NOTES: ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all the transmitters once you're in the programming mode. ^ To keep the system from exiting the programming mode, complete each step within 5 seconds of the previous step, and program the transmitters within 10 seconds of each other. 1. Turn the ignition switch ON (II). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8428 2. Press and hold the Valet-Disarm button on the radio (between the AM/FM button and the CD/TAPE button) to enter the programming mode. (Continue to hold the button during the procedure, or programming will be cancelled.) Check that the power door locks cycle to confirm that you're in the programming mode. 3. Press the "LOCK" or "UNLOCK" button on the transmitter. Check that the power door locks cycle to confirm that the code was accepted. 4. Press the "LOCK" or "UNLOCK" button on all other transmitters. (You can program up to four transmitters per vehicle.) 5. After all the transmitters have been programmed, release the Valet-Disarm button to exit the programming mode. Ordering the Transmitter Transmitters can be ordered only by authorized Honda Dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. Procedure 9 NOTES: ^ The system uses a stacking-type memory that accepts up to four transmitters. If you program a fifth transmitter, the memory for the first transmitter is pushed out, and it will no longer work. ^ To clear a lost or stolen transmitter from the system's memory, program a transmitter four times. This will remove the missing transmitter from memory, since only four transmitter codes can be accepted. Programming the Transmitter Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8429 1. Locate the security system control unit mounted under the driver's seat. 2. Rub your finger over the label on the top of the control unit until you find the depression. Once you find it, push your finger through the label to expose the hole underneath. Inside the hole is a square, yellow button; this is the programming button. 3. Turn the ignition switch on, then turn it off. 4. Press and hold the programming button. Check that the security siren emits four separate chirps followed by a five-chirp burst to confirm that you're in the programming mode. The siren then emits prompting chirps at three-second intervals. 5. Release the programming button. 6. After a prompting chirp, press the "LOCK" button on the transmitter. Check that the siren emits a confirmation chirp to let you know that the transmitter's code was accepted by the control unit. If you wait more than 30 seconds after the prompting chirp before programming a transmitter or between programming transmitters, the siren emits three chirps, and the system exits the programming mode. 7. To program additional transmitters, wait for another prompting chirp, then press the "LOCK" button. (You can program up to four transmitters per vehicle.) 8. To exit the programming mode, turn the ignition switch on, then turn it off. 9. Push all the function buttons on each transmitter to make sure they work correctly. Ordering the Transmitter Transmitters can be ordered only by authorized Honda Dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is 23-144 (Radio Shack), A-23 (Eveready), or MS-21/MN-21 (Duracell). Each transmitter uses one battery. Procedure 10 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8430 Programming the Transmitter NOTES: ^ The system uses a stacking-type memory that accepts up to four transmitters. If you program a fifth transmitter, the memory for the first transmitter is pushed out, and it will no longer work. ^ To clear a lost or stolen transmitter from the system's memory, program a transmitter four times, This will remove the missing transmitter from memory, since only four transmitter codes can be accepted. ^ Another way to clear a lost or stolen transmitter is to erase all transmitter codes and then reprogram them. To do this, refer to the security system owner's manual. 1. Move the driver's seat forward, and locate the security system control unit mounted on the floor, underneath the seat. 2. Turn the ignition switch on. 3. Press and hold the green programming button on the side of the control unit with a pen or pencil. When the security system LED on the instrument panel comes on, release the programming button. (Steps 3 and 4 must be done within 5 seconds of each other.) 4. Press and release the top button on the transmitter. Check that the LED goes out, the siren chirps once, and the front marker lights flash to confirm that the transmitter's code was accepted by the control unit. 5. If you have other transmitters to program, repeat steps 3 and 4. 6. Turn the ignition switch off to exit the programming mode. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Information > Page 8431 Ordering the Transmitter Transmitters can be ordered only by authorized Honda Dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. One battery per transmitter is needed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Driver's Power Door Lock Actuator Power Door Lock Actuator: Locations Driver's Power Door Lock Actuator Rear Of Driver's Door Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Driver's Power Door Lock Actuator > Page 8437 Power Door Lock Actuator: Locations Rear Door Lock Actuator Rear Of Left Rear Door (Right Similar) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Driver's Power Door Lock Actuator > Page 8438 Power Door Lock Actuator: Locations Right Front Door Lock Actuator Rear Of Right Front Door Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Locations Power Door Lock Control Module: Locations Front Of Driver's Door Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions Mirrors: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 8446 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 8447 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 8448 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 8449 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 8450 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 8451 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 8452 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 8453 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 8454 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 8455 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 8456 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 8457 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 8458 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 8459 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 8460 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 8461 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 8462 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 8463 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 8464 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 8465 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 8466 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 8467 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 8468 Mirrors: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 8469 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 8470 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 8471 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 8472 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 8473 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 8474 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 8475 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 8476 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 8477 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 8478 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 8479 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 8480 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 8481 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 8482 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 8483 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 8484 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 8485 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 8486 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 8487 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 8488 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 8489 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 8490 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 8491 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 8492 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 8493 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 8494 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 8495 Power Mirrors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Page 8496 Mirrors: Description and Operation The two outside mirrors are controlled by the power mirror switch. Each mirror has two reversible motors: one motor moves the mirror up and down and the other motor moves the mirror left and right. The power mirror switch contains three switches to control mirror direction, and two switches to select the left or right mirror. With the ignition in ON (II), battery voltage is supplied to the power mirror switch. The mirror selector switch directs voltage from two of the direction switches to either the left or the right mirror. Each direction switch is used for more than one function. Mirror Up Operation With the power mirror switch in the up position, switch 1 is moved to the A position. Switch 1 applies battery voltage to both the left and right power mirror up/down motors. If the mirror selector switch is in the left position, the left up/down motor is grounded through the mirror selector switch and switch 2 in the B position to G551 (Sedan) or G552 (Coupe, Hatchback). If the right mirror up/down motor is selected it is also grounded through switch 2 in the B position. Mirror Down Operation With the power mirror switch in the down position, switches 2 and 3 are moved to the A position. Switch 2 applies battery voltage to the left or right power mirror up/down motor as determined by the mirror selector switch. The selected mirror motor is grounded through switch 1 in the B position to G551 (Sedan) or G552 (Coupe, Hatchback). When switch 2 is moved to position A, it also applies battery voltage to the selected mirror left/right motor. With switch 3 in the A position, battery voltage is supplied to both sides of the left/right motor so it does not move. Mirror Left Operation With the power mirror switch in the left position, switches 1 and 2 are moved to the A position. Switch 2 applies battery voltage to the left or right power mirror left/right motor as determined by the mirror selector switch. The selected mirror motor is grounded through switch 3 in the B position to G551 (Sedan) or G552 (Coupe, Hatchback). When switch 2 is moved to position A, it also applies battery voltage to the selected mirror up/down motor. With switch 1 in the A position, battery voltage is supplied to both sides of the up/down motor so it does not move. Mirror Right Operation With the power mirror switch in the right position, switch 3 is moved to the A position. Switch 3 applies battery voltage through the mirror selector switch to the left or right left/right motor. The motor is grounded through the mirror selector switch and switch 2 in the B position to G551 (Sedan) or G552 (Coupe, Hatchback). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Industrial Fallout Paint Damage Paint: Technical Service Bulletins Paint - Industrial Fallout Paint Damage 99-062 January 15, 2007 Applies To: ALL Paint Damage From Environmental Fallout (Supersedes 99-062, dated October 12, 1999 to update the information marked by the black bars and asterisks) SYMPTOM The exterior paint surface does not feel smooth after the vehicle is washed. PROBABLE CAUSE Environmental fallout (airborne metallic particles, tree sap, paint overspray, road tar, insect residue, etc.) has adhered to the exterior paint surface. NOTE: This form of paint damage should not be confused with acid rain damage. Unlike environmental fallout damage, acid rain damage appears on the paint surface as pits or water spots-possibly black or brown in the center-which may feel smooth to the touch. PREVENTION The shipping wax/wrap guard applied to the vehicle at the factory provides the best protection for the paint finish from environmental fallout and acid rain damage. American Honda strongly recommends that you leave the shipping wax/wrap guard on the vehicle for as long as possible. Your dealership is responsible for maintaining the vehicle's finish after the shipping wax/ wrap guard is removed. CORRECTIVE ACTION Select a product line from one of the manufacturers listed in REQUIRED MATERIALS to clean the paint surface and to wax it after cleaning. Make sure you follow the manufacturer's instructions for each of the products you use. REQUIRED MATERIALS Each of the clays listed should do at least three vehicles. WARRANTY CLAIM INFORMATION Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Industrial Fallout Paint Damage > Page 8502 In warranty: American Honda will reimburse for this repair only under these conditions: ^ It is done during PDI ^ No more than 30 days have elapsed since the vehicle was received at the dealership (according to the date noted on the motor carrier's bill of lading) Operation number: 812355 Flat rate time: 1.0 hour Failed P/N: PDI-PAINT, H/C 3173994 *Defect code: 08103 Symptom code 08811* Skill level: Repair Technician *NOTE: When submitting the claim, make sure you enter the vehicle's date of receipt in the customer contention comment section. The claim will be rejected without this information.* REPAIR PROCEDURE 1. Wash and dry the vehicle out of direct sunlight. 2. Tear off a piece of clay. Shape the piece with your hands into a flat disk about 3 inches in diameter. 3. Spray a 2-to 3-square-foot area of the affected panel with the manufacturer's lubricant. 4. Clean a 1-square-foot section of the sprayed area by rubbing it with the clay. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Industrial Fallout Paint Damage > Page 8503 5. Check your work by running your fingers over the cleaned and lubricated surface to feel for any remaining contamination. ^ If you feel any particles on the cleaned surface fold the clay in half, knead it back into a disk shape, clean the section again, and recheck your work. ^ If the cleaned surface feels smooth, fold the clay in half, knead it back into a disk shape, and go to step 6. NOTE: You must carefully fold and knead the clay to keep a clean side next to the paint surface. Never use clay that has fallen on the ground. Any small pieces of dirt or sand that imbed in the clay will scratch the paint surface. If the clay falls on the ground, discard it and get a fresh piece. 6. Clean the remaining sections of the sprayed area (repeat steps 4 and 5). 7. Wipe the lubricant from all the cleaned sections with a clean terry cloth towel. 8. Clean the rest of the affected panel and any additional panels that need cleaning (repeat steps 3 thru 7). 9. Apply the manufacturer's recommended wax or glaze to all the cleaned panels. Disclaimer Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Industrial Fallout Paint Damage > Page 8504 Technical Service Bulletin # 97-028 Date: 970331 Body - Minor Paint Finish Repair 97-028 Applies To: ALL Models March 31, 1997 Minor Paint Finish Repair The first thing a new vehicle owner sees when he or she takes delivery of a new vehicle is the paint finish. Therefore, making the vehicle look good is very important. However, customer feedback has pointed out that many new vehicles are delivered with scratches and swirl marks. This is especially true with dark colored vehicles. CORRECTIVE ACTION Repair the paint finish using the tools, supplies, and procedures recommended for the type of damage (scratches, swirl marks, etc.) and for the color of the paint WARRANTY CLAIM INFORMATION None: Information only. RECOMMENDED TOOLS AND SUPPLIES To repair the paint finish, you should use these tools and supplies: Tools and Safety Equipment Mil gauge (film thickness gauge) * Pro Gauge II, or equivalent * ETG (Electronic Thickness Gauge), or equivalent These mil gauges are commercially available. They can be purchased from Pro Motorcar Products at 800-334-2843. - Variable speed electric polisher - Dual action orbital polisher (electric or pneumatic) - Eye protection (face shield or safety goggles) Supplies 9" Foam polishing pads (do not use wool type) - Clean, 100% cotton terry cloth towels or soft flannel cloth - Wet/dry sandpaper (1500 - 2000 grit) - Soft sanding pad - 50/50 Solution of isopropyl alcohol and water While we cannot recommend one manufacturer over another, any of the manufacturers listed here can provide you with quality products through their nationwide distributor network. Contact them for your paint repair supply needs, choose one, and then use the system of only that one manufacturer. If you need to know how to use the products, ask the manufacturer for training. 3M Automotive Trades Division 22100 Telegraph Road P.O. Box 358 Southfield, MI 48037-0358 Phone Number: 800-521-8180 Ext. 6890 Meguiar's 17991 Mitchell South Irvine, CA 92714 Phone Number: 800-347-5700 MOC Products 12306 Montague Street Pacoima, CA 91331 Phone Number: 818-896-2258 Repair Procedure The following procedures may not apply to all conditions or colors. Use the procedure that best suits the condition and color of the vehicle you're Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Industrial Fallout Paint Damage > Page 8505 repairing. Repairing and Polishing the Painted Surface The goal of a minor paint repair is to correct the damage to the upper layer of the painted surface. This is done by removing a thin layer of paint (no more than 0.5 mil) and then restoring the luster by polishing the repaired surface. A quick way to determine the depth of a scratch in the paint is to run your fingernail across the scratch. If your fingernail catches on the scratch, the area will need to be wet sanded and polished. When doing scratch or swirl mark repairs, use only quality products from one manufacturer. Each manufacturer has its own set of paint repair products that have matching materials. Mixing materials from different manufacturers, or using inexpensive products, compromises the repair quality. An electric polisher with an adjustable rpm control set between 1,500 and 1,800 rpm is best for polishing. When using a polisher, faster is not better. Too much polisher speed and too much applied force can cause swirl marks or may even burn the paint. Removing Swirl Marks Most swirl marks can be removed by using a foam polishing pad and polishing material. Use the polisher at 1,500 to 1,800 rpm with a small amount of polishing material on the pad. Always begin with the finest polishing material. If necessary, progress to the next coarser material only when the fine materials are ineffective. When polishing, work in small sections (approximately 24" x 24"). Avoid running the polishing pad over edges of a body panel or body lines where the paint is more susceptible to burning through. Let the cleaner do the work. Do not apply too much force! Forcing the polishing pad could cause deep cuts into the paint and might damage the surface so badly that it would need to be repainted. Polishing Dark Colors This additional procedure, after the polishing process described above, is important to reduce any chance of swirl marks, which show more on dark colors. When polishing is completed, use the same type of foam polishing pad on a random orbital polisher. Apply the finest polishing material to a 24" x 24" work area. Start the polisher, and make three to four passes over the work area. Remove the glaze residue with a cotton terry cloth or soft flannel cloth. Wet Sanding This process is used to repair scratches and acid rain damage deeper than 0.2 mil. The object is to remove as little paint material as possible. When wet sanding, stop frequently and dry the work area. This will allow you to see if the wet sanding has removed the damage. Start by soaking a 1500 or 2000 grit wet/dry sanding paper in water for 15 minutes. Wrap the soaked wet/dry sanding paper around a soft sanding pad. Lightly sand in one direction across (90 degrees) the scratched surface to highlight the surface damage. Flush the area with clean water. To remove any sanding scratches left by the wet sanding process, use a foam polishing pad and a polishing material. Refer to Removing Swirl Marks. Final Inspection When the polishing process is done, the paint surface may look perfect, but residue can hide very fine scratches that will become apparent after a few washings. This is especially true for darker colors. Start the final inspection by spraying a 50/50 solution of isopropyl alcohol and water on the work area and then wiping it dry. NOTE: Avoid spraying the solution on any unpainted plastic parts such as taillights, turn signal lenses, reflectors, etc. The solution can cause cracking. Inspect the repaired area, and repeat the polishing process if necessary. Finish the inspection by waxing the completed vehicle with a high quality wax. Use the wax recommended by the paint repair supplies manufacturer you have chosen. Preventive Maintenance Avoiding scratches and dents while the vehicle is in your dealership inventory requires some preventive maintenance. To help reduce the occurrence of scratches and dents, follow these recommendations: Park vehicles far enough apart to prevent door dents and dings. - Leave the exterior shipping protection on the vehicle until it is ready to be sold. - Implement and use an inventory age control system. - Use deionized water to reduce water spotting. - Wash the vehicles with deionized water, soap, and a wash mitt at least once a week. NOTE: Using a wash mitt will remove any residual dirt from the paint surface. If a wash mitt is not used, the residual dirt on the painted surface will scratch the paint when the surface is dried with a chamois or towel. - Use a clean chamois or terry cloth towel to dry the vehicles. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Industrial Fallout Paint Damage > Page 8506 Paint: Technical Service Bulletins Body - Vehicle Paint Codes Model 1995 Applicable To ALL File Under BODY Bulletin No. 94-035 Issue Date JAN 30, 1995 1995 Honda Paint Codes (Supersedes 94-O35, dated Oct. 24, 1994) Paint formulations are determined by each paint company. For questions about formulas or matching, contact your local paint distributor or the paint company's nearest regional office. The information provided is for reference only. American Honda does not endorse any paint company or type of paint. The original paint is acrylic enamel. Paint codes with "M" are metallic colors; those with "P" are pearlescent colors. NOTE: Herberts Standox uses the Honda Paint Code as its paint intermix code. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Industrial Fallout Paint Damage > Page 8507 Japan - Produced Cars Canada - Produced Civics. paint code ends in -4 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Industrial Fallout Paint Damage > Page 8508 U.S.- Produced (Marysville) Accords, paint code ends in -3 U.S.- Produced (East Liberty) Civics, paint code ends in -5 (East Liberty uses waterborne paints) NOTES: The numbers following the paint description represent the paint process used during manufacture of the vehicle: 1 A clear coat is applied over the color coat 2 A small amount of color is mixed with a clear coat and applied over the color coat. 3 A clear coat was not applied at the factory. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Locations Power Door Lock Control Module: Locations Front Of Driver's Door Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof/Moonroof Relay <--> [Sunroof / Moonroof Relay] > Component Information > Locations > Moonroof Close Relay Sunroof/Moonroof Relay: Locations Moonroof Close Relay Behind Left Side Of Dash Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof/Moonroof Relay <--> [Sunroof / Moonroof Relay] > Component Information > Locations > Moonroof Close Relay > Page 8517 Sunroof/Moonroof Relay: Locations Moonroof Open Relay Behind Left Side Of Dash Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Technical Service Bulletins > Customer Interest for Sun Shade: > 95021 > Apr > 95 > Interior Sunshade Rattle Sun Shade: Customer Interest Interior - Sunshade Rattle Bulletin No. 95-021 Issue Date APRIL 10, 1995 Model 1993-95 CIVIC Applicable To See VEHICLES AFFECTED File Under BODY Sunshade Rattle SYMPTOM The sunshade rattles when driving on rough roads. PROBABLE CAUSE The sunshade rail is hitting against the moonroof drain panel. VEHICLES AFFECTED 1993-94: Coupe EX - All 3-door Si - All 1995: Coupe EX - Thru VIN 1HGEJ1...SL003852 Thru VIN 2HGEJ1...SH512447 3-door Si - Thru VIN 2HGEH3...SH508207 REQUIRED MATERIALS EPT Sealer 5T: P/N 06991-SA5-000, H/C 2086650 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. Operation number: 814001 Flat rate time: 0.3 hour Failed part: P/N 83210-SR3-AO1ZA H/C 3963147 Defect code: 043 Contention code: B07 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Technical Service Bulletins > Customer Interest for Sun Shade: > 95021 > Apr > 95 > Interior Sunshade Rattle > Page 8528 CORRECTIVE ACTION Separate the sunshade rail from the moon roof drain panel with EPT Sealer ST (see REQUIRED MATERIALS). 1. Tilt up the back of the moonroof. Do not slide it back. 2. Slide the sunshade all the way back. 3. Cut two 40 x 15 mm pieces of EPT Sealer 5T. Fold them in half lengthwise, sticky side together. 4. Pull up on the moon roof drain panel and insert a piece of EPT between it and the sunshade rail. 5. While still pulling up on the drain panel, use a small screwdriver to push the EPT completely under the drain panel. Make sure the EPT is on the rail and not overlapping onto the sunshade. 6. Repeat steps 4 and 5 on the other side. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sun Shade: > 95021 > Apr > 95 > Interior - Sunshade Rattle Sun Shade: All Technical Service Bulletins Interior - Sunshade Rattle Bulletin No. 95-021 Issue Date APRIL 10, 1995 Model 1993-95 CIVIC Applicable To See VEHICLES AFFECTED File Under BODY Sunshade Rattle SYMPTOM The sunshade rattles when driving on rough roads. PROBABLE CAUSE The sunshade rail is hitting against the moonroof drain panel. VEHICLES AFFECTED 1993-94: Coupe EX - All 3-door Si - All 1995: Coupe EX - Thru VIN 1HGEJ1...SL003852 Thru VIN 2HGEJ1...SH512447 3-door Si - Thru VIN 2HGEH3...SH508207 REQUIRED MATERIALS EPT Sealer 5T: P/N 06991-SA5-000, H/C 2086650 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. Operation number: 814001 Flat rate time: 0.3 hour Failed part: P/N 83210-SR3-AO1ZA H/C 3963147 Defect code: 043 Contention code: B07 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sun Shade: > 95021 > Apr > 95 > Interior - Sunshade Rattle > Page 8534 CORRECTIVE ACTION Separate the sunshade rail from the moon roof drain panel with EPT Sealer ST (see REQUIRED MATERIALS). 1. Tilt up the back of the moonroof. Do not slide it back. 2. Slide the sunshade all the way back. 3. Cut two 40 x 15 mm pieces of EPT Sealer 5T. Fold them in half lengthwise, sticky side together. 4. Pull up on the moon roof drain panel and insert a piece of EPT between it and the sunshade rail. 5. While still pulling up on the drain panel, use a small screwdriver to push the EPT completely under the drain panel. Make sure the EPT is on the rail and not overlapping onto the sunshade. 6. Repeat steps 4 and 5 on the other side. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Locations > Photo 102 Sunroof / Moonroof Motor: Locations Photo 102 Center Front Of Roof Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Locations > Photo 102 > Page 8539 Sunroof / Moonroof Motor: Locations Photo 103 Center Rear Of Roof Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof/Moonroof Relay <--> [Sunroof / Moonroof Relay] > Component Information > Locations > Moonroof Close Relay Sunroof/Moonroof Relay: Locations Moonroof Close Relay Behind Left Side Of Dash Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof/Moonroof Relay <--> [Sunroof / Moonroof Relay] > Component Information > Locations > Moonroof Close Relay > Page 8544 Sunroof/Moonroof Relay: Locations Moonroof Open Relay Behind Left Side Of Dash Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations > Open/Close Switch Sunroof / Moonroof Switch: Locations Open/Close Switch Center Rear Of Roof Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations > Open/Close Switch > Page 8549 Sunroof / Moonroof Switch: Locations Tilt/Close Switch Center Rear Of Roof Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Technical Service Bulletins > Customer Interest for Head Rest: > 95022 > Apr > 95 > Interior - Gap In Headrest Support Cover Head Rest: Customer Interest Interior - Gap In Headrest Support Cover Bulletin No. 95-022 Issue Date APRIL 17, 1995 Model 1994-95 CIVIC Applicable To See VEHICLES AFFECTED File Under BODY Gap in Headrest Support Cover SYMPTOM The gap between the front and back pieces of the headrest support cover is too large. PROBABLE CAUSE A clip on the rear cover piece is too long. VEHICLES AFFECTED CORRECTIVE ACTION Replace the clip on the rear cover piece with the shorter Clip listed under PARTS INFORMATION. 1. Remove the headrest support covers. Cover your prying tool with protective tape or a shop towel so you do not scratch the covers. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Technical Service Bulletins > Customer Interest for Head Rest: > 95022 > Apr > 95 > Interior - Gap In Headrest Support Cover > Page 8559 2. Remove the outer clip from the rear cover. The rear cover is marked RR. 3. Install the new Clip listed under PARTS INFORMATION. 4. Reinstall the support cover. 5. If necessary, repeat steps 1 through 4 on the other side. PARTS INFORMATION Outer clip: P/N 90610-SR3-999, H/C 4751228 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. Operation number: 860301 Flat rate time: 0.3 hour for both sides Failed part: P/N 90609-SG0-003, H/C 2601466 Defect code: 074 Contention code: B01 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Head Rest: > 95022 > Apr > 95 > Interior - Gap In Headrest Support Cover Head Rest: All Technical Service Bulletins Interior - Gap In Headrest Support Cover Bulletin No. 95-022 Issue Date APRIL 17, 1995 Model 1994-95 CIVIC Applicable To See VEHICLES AFFECTED File Under BODY Gap in Headrest Support Cover SYMPTOM The gap between the front and back pieces of the headrest support cover is too large. PROBABLE CAUSE A clip on the rear cover piece is too long. VEHICLES AFFECTED CORRECTIVE ACTION Replace the clip on the rear cover piece with the shorter Clip listed under PARTS INFORMATION. 1. Remove the headrest support covers. Cover your prying tool with protective tape or a shop towel so you do not scratch the covers. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Head Rest: > 95022 > Apr > 95 > Interior - Gap In Headrest Support Cover > Page 8565 2. Remove the outer clip from the rear cover. The rear cover is marked RR. 3. Install the new Clip listed under PARTS INFORMATION. 4. Reinstall the support cover. 5. If necessary, repeat steps 1 through 4 on the other side. PARTS INFORMATION Outer clip: P/N 90610-SR3-999, H/C 4751228 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. Operation number: 860301 Flat rate time: 0.3 hour for both sides Failed part: P/N 90609-SG0-003, H/C 2601466 Defect code: 074 Contention code: B01 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Fabric Upholstery Wrinkle Information Seat Cover: Technical Service Bulletins Interior - Fabric Upholstery Wrinkle Information Use a Steamer to Smooth Out Fabric Upholstery A garment steamer and a stiff-bristle brush make a great team for removing those nasty wrinkles, lines, or impressions in fabric upholstery. You can buy an inexpensive, small, hand-held garment/ fabric steamer from a number of different manufacturers. Some of these units even come with a handy built-in brush. Once you've got your steamer, follow the manufacturer's instructions to get it ready for use. Then apply a generous amount of steam to the problem area. Keep the steamer moving slowly over the area until it's hot and moist. A Word of Caution: Go easy on the steam if you're cleaning the front passenger seat in a vehicle with side airbags. Moisture can adversely affect or damage the OPDS sensors in the seatback. While the area is hot and moist, use a stiff-bristle brush, or the built-in brush if your steamer has one, to work the fabric back and forth and up and down. Stubborn areas might need more steam and brushing, so be patient and stay with it. It's worth the effort. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Open/Close Switch Sunroof / Moonroof Switch: Locations Open/Close Switch Center Rear Of Roof Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Open/Close Switch > Page 8575 Sunroof / Moonroof Switch: Locations Tilt/Close Switch Center Rear Of Roof Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Splash Guard > Component Information > Technical Service Bulletins > Customer Interest for Splash Guard: > 95033 > Aug > 95 > Engine - Splash Shield Knocks Off the A/C Belt Splash Guard: Customer Interest Engine - Splash Shield Knocks Off the A/C Belt BULLETIN NO. 95-033 ISSUE DATE: AUG 14, 1995 MODEL: 1992-95 CIVIC APPLICABLE TO ALL WITH A/C FILE UNDER BODY Engine Splash Shield Knocks Off the A/C Belt SYMPTOM The A/C system does not cool because the compressor belt has come off. PROBABLE CAUSE The engine splash shield may go over a parking lot stop when the car is driven into a parking space. When the driver then backs the car up, the splash shield may catch on the stop, which causes the splash shield to flex. The splash shield comes in contact with the A/C compressor belt, knocking it off the pulleys. CORRECTIVE ACTION Modify the splash shield to improve flexibility. If the existing splash shield is damaged, modify a new splash shield and install it. 1. Remove the engine splash shield. 2. Inspect the splash shield for damage. If it is no longer usable, obtain a new one (see PARTS INFORMATION) before proceeding. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Splash Guard > Component Information > Technical Service Bulletins > Customer Interest for Splash Guard: > 95033 > Aug > 95 > Engine - Splash Shield Knocks Off the A/C Belt > Page 8584 3. Use a die grinder to remove 20 mm from the five support ribs shown. Smooth and radius the back edge of each rib after removing the material. 4. Cut a 10 x 35 mm slot on the left side of the center support rib. 5. Cut a 10 x 30 mm slot on the left side of the splash shield. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Splash Guard > Component Information > Technical Service Bulletins > Customer Interest for Splash Guard: > 95033 > Aug > 95 > Engine - Splash Shield Knocks Off the A/C Belt > Page 8585 6. Radius one edge of each slot as shown. 7. Install the splash shield on the vehicle. PARTS INFORMATION Engine splash shield: P/N 74111-SR3-A00, H/C 3889847 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. Operation number: 810011 Flat rate time: 0.5 hour Failed part: P/N 74111-SR3-A00 H/C 3889847 Defect code: 004 Contention code: B01 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Splash Guard > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Splash Guard: > 95033 > Aug > 95 > Engine - Splash Shield Knocks Off the A/C Belt Splash Guard: All Technical Service Bulletins Engine - Splash Shield Knocks Off the A/C Belt BULLETIN NO. 95-033 ISSUE DATE: AUG 14, 1995 MODEL: 1992-95 CIVIC APPLICABLE TO ALL WITH A/C FILE UNDER BODY Engine Splash Shield Knocks Off the A/C Belt SYMPTOM The A/C system does not cool because the compressor belt has come off. PROBABLE CAUSE The engine splash shield may go over a parking lot stop when the car is driven into a parking space. When the driver then backs the car up, the splash shield may catch on the stop, which causes the splash shield to flex. The splash shield comes in contact with the A/C compressor belt, knocking it off the pulleys. CORRECTIVE ACTION Modify the splash shield to improve flexibility. If the existing splash shield is damaged, modify a new splash shield and install it. 1. Remove the engine splash shield. 2. Inspect the splash shield for damage. If it is no longer usable, obtain a new one (see PARTS INFORMATION) before proceeding. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Splash Guard > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Splash Guard: > 95033 > Aug > 95 > Engine - Splash Shield Knocks Off the A/C Belt > Page 8591 3. Use a die grinder to remove 20 mm from the five support ribs shown. Smooth and radius the back edge of each rib after removing the material. 4. Cut a 10 x 35 mm slot on the left side of the center support rib. 5. Cut a 10 x 30 mm slot on the left side of the splash shield. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Splash Guard > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Splash Guard: > 95033 > Aug > 95 > Engine - Splash Shield Knocks Off the A/C Belt > Page 8592 6. Radius one edge of each slot as shown. 7. Install the splash shield on the vehicle. PARTS INFORMATION Engine splash shield: P/N 74111-SR3-A00, H/C 3889847 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. Operation number: 810011 Flat rate time: 0.5 hour Failed part: P/N 74111-SR3-A00 H/C 3889847 Defect code: 004 Contention code: B01 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Unibody > Component Information > Technical Service Bulletins > Body Unibody Repair Guidelines Unibody: Technical Service Bulletins Body - Unibody Repair Guidelines 07-008 February 2, 2007 Applies To: ALL Clarification of Honda Unibody Repair Policy BACKGROUND Honda automobiles and trucks are built to precise standards so that they can perform well under many situations. For example, they offer a firm responsive ride yet yield when necessary under the forces of a collision to help protect the vehicle occupants. HONDA REPAIR POLICY Sectioning Frame Components When body repairs are necessary, Honda recommends that any repairs be performed by an experienced professional, using the Honda body repair manual, and that component replacement be accomplished along factory seams. Failure to do so can result in a number of problems, including improperly fitting parts, noises, tire wear, and most importantly, changes in vehicle dynamics and occupant protection in a subsequent crash. In particular, Honda strongly recommends against the process of joining cut pieces from separate vehicle~commonly referred to as clipping. This is not an authorized Honda repair method. Any problem with other components resulting from such improper vehicle repairs is not covered under Honda's factory or extended warranties. Also, because what's in a part is as important as how it looks, Honda strongly recommends the use of Honda Genuine repair parts. The material used to create the part, such as high-strength steel, and the subtle shapes of the part, determine how it will perform in normal operation or in a subsequent collision. Using Honda Genuine repair parts helps return the vehicle to its pre-crash condition. ADHESIVES/WELDING Using adhesives in place of welding for component replacement is not an authorized Honda repair method. It is important to repair at factory seams using the same procedure as the factory assembly process except where specified otherwise in the Honda body repair manual. The door skin is welded at the top and is glued around the crimp. Each body repair manual states that if the reinforcement in the door is damaged, the complete door must be replaced. NOTE: Because they are made of high-strength steel, door and bumper reinforcements must not be repaired or straightened. INFORMATION RESOURCES Extensive research and development goes into every Honda to provide safety for those inside as well as outside the vehicle. Therefore, it is critical that collision repair facilities do not change a vehicle during collision repair. Please visit the following websites for further information about Honda safety: ^ world.honda.com/safety, and ^ world.honda.com/news/2003/4030904_2.html Body repair manuals are available for every new Honda model series that is sold in the U.S. Each manual provides instructions for proper repair procedures, and drawings that show where each factory seam and weld on the vehicle is located. In a few instances, the manual also indicates where it is acceptable to cut panels and sections other than at factory seams. Body repair manuals can be purchased from Helm, Inc. using one of these methods: ^ Call Helm Inc. at 1-800-782-4356 ^ Go online at www.helminc.com Collision repair facilities can also subscribe to all manuals at www. serviceexpress.honda.com. Dealers can log onto ISIS and view body repair manuals in the Search By Publication section. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Unibody > Component Information > Technical Service Bulletins > Body Unibody Repair Guidelines > Page 8597 Disclaimer Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 92021 > Apr > 95 > Door - Weatherstrip Detached or Deformed Weatherstrip: Customer Interest Door - Weatherstrip Detached or Deformed Bulletin No. 92-021 Issue Date April 17, 1995 Model [NEW] 1992-95 Civic 4-door Applicable to [NEW] All File Under Body Rear Door Weatherstrip Detached or Deformed (Supersede 92-021, Wind Noise From Rear Door, dated June 19, 1992) PROBLEM [NEW] A section of the weatherstrip on the rear door(s) has come loose, possibly causing it to get deformed or torn by the door. CORRECTIVE ACTION Reattach or replace the weatherstrip. 1. Remove the retaining clip that holds the weatherstrip to the door. 2. Examine the weatherstrip. If it is torn, remove and discard it. If it is OK, lift about 4 mm on each side of the affected area. 3. Clean the door sash and the weatherstrip in the affected area with isopropyl alcohol, and allow it to dry. 4. Apply a 4 mm x 150 mm bead of 3M Weatherstrip Adhesive (P/N 051135-08011) to the door sash and the weatherstrip. NOTE: Careful application of the weatherstrip adhesive will minimize cleanup. Remove traces of weatherstrip adhesive with 3M Adhesive Cleaner, 3M P/N 051135-08904. 5. Wait until the adhesive is tacky, then reinstall the weatherstrip. 6. Leave the door open for 5 to 10 minutes to allow for complete drying. PARTS INFORMATION Weatherstrip, right door: P/N 72810-SR4-003, H/C 3889235 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 92021 > Apr > 95 > Door - Weatherstrip Detached or Deformed > Page 8606 Weatherstrip, left door: P/N 72850-SR4-003, H/C 3889292 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. Failed part, right door: P/N 72810-SR4-003 H/C 3889235 Failed part, left door: P/N 72850-SR4-003 H/C 3889292 Defect code: 056 Contention code: B07 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 92021 > Apr > 95 > Door - Weatherstrip Detached or Deformed Weatherstrip: All Technical Service Bulletins Door - Weatherstrip Detached or Deformed Bulletin No. 92-021 Issue Date April 17, 1995 Model [NEW] 1992-95 Civic 4-door Applicable to [NEW] All File Under Body Rear Door Weatherstrip Detached or Deformed (Supersede 92-021, Wind Noise From Rear Door, dated June 19, 1992) PROBLEM [NEW] A section of the weatherstrip on the rear door(s) has come loose, possibly causing it to get deformed or torn by the door. CORRECTIVE ACTION Reattach or replace the weatherstrip. 1. Remove the retaining clip that holds the weatherstrip to the door. 2. Examine the weatherstrip. If it is torn, remove and discard it. If it is OK, lift about 4 mm on each side of the affected area. 3. Clean the door sash and the weatherstrip in the affected area with isopropyl alcohol, and allow it to dry. 4. Apply a 4 mm x 150 mm bead of 3M Weatherstrip Adhesive (P/N 051135-08011) to the door sash and the weatherstrip. NOTE: Careful application of the weatherstrip adhesive will minimize cleanup. Remove traces of weatherstrip adhesive with 3M Adhesive Cleaner, 3M P/N 051135-08904. 5. Wait until the adhesive is tacky, then reinstall the weatherstrip. 6. Leave the door open for 5 to 10 minutes to allow for complete drying. PARTS INFORMATION Weatherstrip, right door: P/N 72810-SR4-003, H/C 3889235 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 92021 > Apr > 95 > Door - Weatherstrip Detached or Deformed > Page 8612 Weatherstrip, left door: P/N 72850-SR4-003, H/C 3889292 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. Failed part, right door: P/N 72810-SR4-003 H/C 3889235 Failed part, left door: P/N 72850-SR4-003 H/C 3889292 Defect code: 056 Contention code: B07 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Cruise Control > Brake Lamp Switch (Cruise Control) <--> [Brake Switch (Cruise Control)] > Component Information > Locations Brake Lamp Switch (Cruise Control): Locations Behind Left Side Of Dash Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Cruise Control > Brake Lamp Switch (Cruise Control) <--> [Brake Switch (Cruise Control)] > Component Information > Locations > Page 8617 Brake Lamp Switch (Cruise Control): Testing and Inspection 1. Disconnect 4-P connector from switch. Fig. 15 Brake Light Switch 2. Check for continuity between terminals, Fig. 15. 3. Adjust pedal height if necessary or replace switch if defective. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Testing and Inspection Clutch Switch: Testing and Inspection 1. Disconnect 2-P connector from switch. Fig. 17 Clutch Switch Components 2. Check for continuity between terminals, Fig. 17. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Locations Cruise Control Module: Locations Left Kick Panel - Photo 53 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Cruise Control > Cruise Control Actuator <--> [Cruise Control Servo] > Component Information > Locations Cruise Control Actuator: Locations Left Front Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Cruise Control > Cruise Control Actuator <--> [Cruise Control Servo] > Component Information > Locations > Page 8627 Cruise Control Actuator: Testing and Inspection 1. Disconnect 4-P connector from actuator. 2. Ensure output linkage moves smoothly. Fig. 13 Actuator Test Components 3. Connect battery positive to terminal D and negative to terminal A, Fig. 13. 4. Ensure magnetic clutch engages and output linkage is locked. 5. If the output linkage is not locked, replace actuator assembly. Fig. 14 Actuator Test 6. Check operation of actuator motor in each output linkage position according to table, Fig. 14. You should be able to hear motor. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Cruise Control > Actuator Cable <--> [Cruise Control Servo Cable] > Component Information > Adjustments Actuator Cable: Adjustments Fig. 7 Actuator Cable Adjustment 1. Check actuator cable for smooth operation. Cable should not bind or stick in proper operating condition. 2. Start engine and measure actuator rod movement until cable pulls on actuator lever when engine speed starts to increase. Refer to Fig. 7 for locknut freeplay measurement. 3. If locknut freeplay is not within specifications, loosen locknut and turn adjusting nut as required, Fig. 7. 4. Tighten locknut and recheck freeplay measurement. 5. Test drive car to ensure proper operation of speed control system. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Cruise Control > Actuator Cable <--> [Cruise Control Servo Cable] > Component Information > Adjustments > Page 8631 Actuator Cable: Service and Repair Actuator/Cable Replacement 1. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. 2. Disconnect battery ground cable. Fig. 44 Actuator Cable Components 3. Pull back boot and loosen locknut, then disconnect cable from bracket, Fig. 44. 4. Disconnect cable end from actuator rod. 5. Disconnect 4-P connector. 6. Pull ventilation hose from grommet. 7. Disconnect vacuum hose from check valve. 8. Remove two actuator mount attaching bolts, then the actuator with bracket and reservoir. 9. Disconnect cable end from linkage over accelerator pedal, then turn grommet 90° in firewall and remove cable. 10. Reverse procedure to install, adjusting actuator cable as necessary. 11. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Testing and Inspection > Main Switch Test/Replacement Cruise Control Switch: Testing and Inspection Main Switch Test/Replacement 1. Carefully remove switch from instrument panel and disconnect electrical connectors. 2. Remove cruise control switch from switch panel. Fig. 29 Main Switch Test 3. Check for continuity between terminals in each switch position according to tables, Fig. 29. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Testing and Inspection > Main Switch Test/Replacement > Page 8636 Cruise Control Switch: Testing and Inspection Set/Resume Switch Test/Replacement 1. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. 2. Disconnect battery ground cable, then the positive cable. 3. Ensure wheels are in straight ahead position, then remove lower instrument panel cover. Fig. 37 Test Harness "C" Installation. W/Air Bag 4. Disconnect cable reel harness 6-P connector from air bag harness, then connect test harness C only to cable reel harness, Fig. 37. Fig. 38 Set/Resume Switch Test. W/Air Bag 5. Check for continuity between terminals of test harness C in each switch position, Fig. 38. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Testing and Inspection > Main Switch Test/Replacement > Page 8637 Fig. 39 Set/Resume Switch Cover Removal 6. Check for continuity between terminals of test harness C in each switch position, Fig. 39. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Testing and Inspection > Main Switch Test/Replacement > Page 8638 Fig. 40 Set/resume Switch Steering Wheel Location Test. W/Air Bag 7. Check for continuity between terminals in each switch position, Fig. 40. 8. If there is no continuity in any position, replace set/resume switch. 9. If there is continuity in every switch position, replace cable reel. 10. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Testing and Inspection > Main Switch Test/Replacement > Page 8639 Cruise Control Switch: Testing and Inspection Shift Lever Position Switch 1. Remove front console. Fig. 43 Shift Lever Position Test 2. Check for continuity between terminals in each switch position, Fig. 43. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations Cruise Control Module: Locations Left Kick Panel - Photo 53 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Lamp Switch (Cruise Control) <--> [Brake Switch (Cruise Control)] > Component Information > Locations Brake Lamp Switch (Cruise Control): Locations Behind Left Side Of Dash Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Lamp Switch (Cruise Control) <--> [Brake Switch (Cruise Control)] > Component Information > Locations > Page 8648 Brake Lamp Switch (Cruise Control): Testing and Inspection 1. Disconnect 4-P connector from switch. Fig. 15 Brake Light Switch 2. Check for continuity between terminals, Fig. 15. 3. Adjust pedal height if necessary or replace switch if defective. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Testing and Inspection Clutch Switch: Testing and Inspection 1. Disconnect 2-P connector from switch. Fig. 17 Clutch Switch Components 2. Check for continuity between terminals, Fig. 17. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Testing and Inspection > Main Switch Test/Replacement Cruise Control Switch: Testing and Inspection Main Switch Test/Replacement 1. Carefully remove switch from instrument panel and disconnect electrical connectors. 2. Remove cruise control switch from switch panel. Fig. 29 Main Switch Test 3. Check for continuity between terminals in each switch position according to tables, Fig. 29. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Testing and Inspection > Main Switch Test/Replacement > Page 8656 Cruise Control Switch: Testing and Inspection Set/Resume Switch Test/Replacement 1. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. 2. Disconnect battery ground cable, then the positive cable. 3. Ensure wheels are in straight ahead position, then remove lower instrument panel cover. Fig. 37 Test Harness "C" Installation. W/Air Bag 4. Disconnect cable reel harness 6-P connector from air bag harness, then connect test harness C only to cable reel harness, Fig. 37. Fig. 38 Set/Resume Switch Test. W/Air Bag 5. Check for continuity between terminals of test harness C in each switch position, Fig. 38. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Testing and Inspection > Main Switch Test/Replacement > Page 8657 Fig. 39 Set/Resume Switch Cover Removal 6. Check for continuity between terminals of test harness C in each switch position, Fig. 39. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Testing and Inspection > Main Switch Test/Replacement > Page 8658 Fig. 40 Set/resume Switch Steering Wheel Location Test. W/Air Bag 7. Check for continuity between terminals in each switch position, Fig. 40. 8. If there is no continuity in any position, replace set/resume switch. 9. If there is continuity in every switch position, replace cable reel. 10. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Testing and Inspection > Main Switch Test/Replacement > Page 8659 Cruise Control Switch: Testing and Inspection Shift Lever Position Switch 1. Remove front console. Fig. 43 Shift Lever Position Test 2. Check for continuity between terminals in each switch position, Fig. 43. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Description and Operation ABS Light: Description and Operation ABS Indicator Light: The ABS indicator light comes on for three seconds and then goes off when the control unit detects no problem during the initial diagnosis right after the engine starts. However, the ABS indicator light can stay on for up to 40 seconds when the control unit starts to check for pump overrun, etc. during the initial diagnosis. The ABS indicator light comes on, and the ABS control unit memorizes the diagnostic trouble code (DTC) under certain conditions. - The parking brake is applied for more than 30 seconds while the vehicle is being driven. (DTC 2-1) - The transmission downshifted excessively. (DTC 4-1, 4-2) - The vehicle loses traction, and the front wheels spin for more than one minute when starting from a stuck condition in mud, snow, or sandy road. (DTC 4-8) - The tires adhesion is lost due to excessive cornering speed. (DTC 5, 5-4, 5-8) - The vehicle is driven on an extremely rough road. (DTC 8-1) - The vehicle is interfered by strong radio waves (noise), for example, illegal radio, etc. (DTC 8-2) NOTE: If there is any trouble in the system, the ABS indicator light turns on during driving. Diagnostic Trouble Code (DTC): - When the control unit detects a problem and the ABS indicator light comes on, the control unit memorizes the DTC. - The control unit has three memory registers. When a problem occurs, the control unit stores the DTC in the first memory register. If another problem occurs, or the same problem occurs again, the control unit moves the first DTC to the next memory register, and stores the second DTC in the first register. If there's a third problem occurrence, the two existing DTCs are moved up one register, and the third DTC is stored in the first register. If problems continue to occur, the oldest problem is moved out of the last register and lost, and the most recent problem is stored in the first register. When the same problem occurs three times, the same DTC is stored in all memory registers. (Refer to the Symptom-to- System Chart for diagnostic period.) - The most recent DTC is indicated first, and the oldest DTC is indicated last. - The DTCs are erased from the control unit when the ABS control unit +B2 power supply or connector is disconnected. - The control unit's memory can be erased by disconnecting the ABS B2 fuse for more than three seconds. Self-diagnosis: - There are three self-diagnoses described below. 1. Initial diagnosis: Performed right after the engine starts until the ABS indicator light goes off. 2 Regular diagnosis: Continuously performed (under some conditions) after the ABS indicator light goes off until the engine stops. 3. Individual part/system diagnosis: Diagnosis about a specific part/system under its operating conditions. - The CPU (central processing unit) controls the following when it detects a problem during self-diagnosis: 1. Turns the ABS indicator light ON. 2. Turns the front and rear fail-safe relays off. 3. Stops the ABS control. 4. Stops the ABS pump. (The pump may work under some conditions.) 5. After the DTC is stored in the control unit, the CPU stops self-diagnosis. Kickback and Pump Operation: - When the engine is started, the ABS control unit begins the initial diagnosis and operates the solenoid valve one time. The kickback may be felt when the brake pedal is depressed. - When the ABS control unit detects the pressure switch OFF signal during the initial diagnosis, it operates the pump motor, and performs the pump motor over-run diagnosis and pump motor diagnosis. Therefore, there are two cases where the pump motor operates or does not operate after the engine is started. - Normally, after the initial diagnosis, the pump motor operates based on the pressure switch signal, regardless of the vehicle speed. Troubleshooting: - When two or three DTCs are stored in the control unit, perform troubleshooting for the DTC that appears first. - When a customer's reported problem cannot be verified on the car, ask the customer about the conditions when the ABS indicator light came ON, and test drive the car under those conditions, if possible. When the ABS indicator light does not come ON during the test, check for loose terminals and check by shaking the harnesses and connectors while following the flowchart. - The connector terminal numbers are viewed from the wire side for the female terminals, and from the terminal side for the male terminals. - After the repair finished off, test drive the car and check the ABS indicator light does not come ON again during the test. (Refer to the Symptom-to-System Chart for diagnostic period.) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Description and Operation > Page 8664 ABS Light: Service and Repair ABS LAMP RESET PROCEDURE ^ If all repairs have been completed, disconnect the ABS B2 (15 A) fuse in the under-hood fuse/relay box for at least three (3) seconds to erase the ABS control unit's memory. NOTE: The ABS control unit's memory will be erased if the connector is disconnected from the ABS control unit or the ABS control unit is removed from the body. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8669 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8670 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8671 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8672 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8673 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8674 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8675 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8676 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8677 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8678 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8679 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8680 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8681 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8682 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8683 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8684 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8685 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8686 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8687 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8688 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8689 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8690 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8691 Audible Warning Device: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8692 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8693 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8694 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8695 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8696 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8697 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8698 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8699 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8700 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8701 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8702 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8703 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8704 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8705 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8706 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8707 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8708 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8709 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8710 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8711 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8712 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8713 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8714 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8715 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8716 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8717 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8718 Seat Belt And Ignition Key Reminders Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Charge Lamp/Indicator > Component Information > Testing and Inspection Charge Lamp/Indicator: Testing and Inspection 1. With ignition switch in On position, charge warning lamp should illuminate. If charge warning lamp is not illuminated, proceed to next numerical step. If charge warning lamp does illuminate perform the following: a. Start engine, charge warning lamp should go off. If charge warning lamp does not go out, continue test. If charge warning lamp does go out, charge warning light system is OK. b. Turn ignition switch to Off position and disconnect 4-P connector from alternator, then turn ignition switch to On position. If charge warning lamp illuminates, repair short to ground in white/blue wire. If charge warning lamp does not illuminate, charge warning light system is OK. 2. Turn ignition switch to Off position and check No. 24 fuse. 3. If fuse is blown, replace it. If fuse is OK, continue test. 4. Disconnect 4-P connector from alternator and turn ignition switch on, then check for voltage at the IG (black/yellow wire) terminal of 4-P connector. If battery voltage is not present, repair open in black/yellow wire. If battery voltage is present, continue test. 5. Ground white/blue wire at L terminal of 4-P connector. If charge warning light does not come on, repair either blown charge system light bulb or open in white/blue wire. If charge warning light does come on, replace voltage regulator. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8726 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8727 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8728 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8729 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8730 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8731 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8732 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8733 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8734 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8735 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8736 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8737 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8738 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8739 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8740 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8741 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8742 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8743 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8744 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8745 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8746 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8747 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8748 Cigarette Lighter: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8749 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8750 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8751 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8752 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8753 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8754 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8755 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8756 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8757 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8758 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8759 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8760 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8761 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8762 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8763 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8764 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8765 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8766 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8767 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8768 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8769 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8770 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8771 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8772 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8773 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8774 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8775 Cigarette Lighter Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions Clock: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8780 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8781 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8782 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8783 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8784 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8785 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8786 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8787 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8788 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8789 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8790 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8791 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8792 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8793 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8794 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8795 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8796 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8797 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8798 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8799 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8800 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8801 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8802 Clock: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8803 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8804 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8805 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8806 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8807 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8808 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8809 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8810 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8811 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8812 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8813 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8814 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8815 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8816 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8817 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8818 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8819 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8820 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8821 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8822 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8823 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8824 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8825 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8826 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8827 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8828 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8829 Clock Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Specifications Air Bag(s) Arming and Disarming: Specifications Component .......................................................................................................................................... ....................................................... Torque/Ft. Lbs. Dash Sensor Mounting Bolts .............................. .............................................................................................................................................................. .. 16 Driver Side Air Bag Assembly To Steering Wheel Bolts ................................................................................................................................................. 7.2 Passenger Side Air Bag Mounting Nuts & Bolts .................................................................................. ............................................................................. 7.2 SRS Unit Mounting Bolts ................................. .............................................................................................................................................................. .. 7.2 Steering Wheel To Column Steering Shaft Nut .......................................................................... ....................................................................................... 36 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Specifications > Page 8834 Air Bag(s) Arming and Disarming: Service Precautions 1. On models with 3-P SRS connectors, install red short connectors on air bags prior to disconnecting any part of SRS wiring harness. 2-P SRS connectors automatically short when disconnected. 2. Always use test harnesses. Do not use test probes directly on component connector pins or wires. 3. When connecting any test harnesses, push connectors straight in until secure. Do not bend connector pins. 4. Always keep red short connector on air bag connector when harness is disconnected. 5. Always store air bag assembly with pad surface facing upward. 6. Do not attempt to disassemble air bag assembly. 7. An air bag that has been deployed cannot be repaired or reused. 8. Keep air bag assembly free of oil and grease. 9. Do not expose air bag assembly to temperatures above 212°F. 10. Do not use SRS components from another vehicle. Always install new replacement components. 11. Do not paint air bag assembly to correct cosmetic flaws. It must be replaced. 12. Inspect all components prior to installation. Do not install any that appear to have been improperly handled or stored or that show any signs of damage. 13. When repairing vehicle, system should be disarmed as outlined under Technician Safety Information. 14. When performing service procedures, do not expose sensors or wiring or other SRS components to heat guns, welding or spray guns. 15. SRS wiring should not be spliced, soldered or repaired. 16. Use only special digital multimeter tool No. KS-AHM-32-003, or equivalent, digital multimeter with 0.0 mA or smaller output when switched to lowest ohmmeter range to inspect system. Analog or testers with higher outputs can damage circuits or cause accidental air bag deployment and, if equipped, seat belt pretensioner activation. 17. Do not bump SRS unit whenever ignition is turned On, or has been Off for less than three minutes. Unwanted deployment could result. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Specifications > Page 8835 Air Bag(s) Arming and Disarming: Service and Repair The Supplemental Restraint System (SRS) must be disarmed prior to disconnecting any electrical connectors or servicing any system components or items located near SRS electrical connectors. SRS electrical wiring can be identified by its yellow outer protective coating. To disarm the SRS, proceed as follows: 1. Obtain five-digit radio theft protection code number. 2. Disconnect battery ground cable, then the positive cable. Fig. 1 Driver Air Bag Disarming 3. After disconnecting cables, wait at least three minutes with ignition turned Off before disconnecting any SRS electrical connectors. This will allow air bag system back-up circuit capacitor to discharge. 4. Remove steering wheel access panel and disconnect electrical connector located between air bag and cable reel, Fig. 1 5. Remove glove compartment and access panel. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Specifications > Page 8836 Fig. 4 Passenger Air Bag Disarming 6. Disconnect front passenger air bag 3-P connector from SRS main harness and connect red short connector, Fig. 4. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Specifications > Page 8837 Fig. 12 Fuse Panel/SRS Connector 7. Using thin blade screwdriver, lift SRS to under-instrument panel fuse connector lid, Fig. 12, then press tab down and slide connector out. 8. Reverse procedure to reactivate system, noting following: a. Slide harness electrical connector onto fuse panel connections until it clicks, then close connector lid. b. Ensure all red short connectors have been removed and placed in their holders. c. Prior to connecting battery ground and positive cables, ensure all supplemental restraint system electrical connectors have been properly connected. d. After battery cables have been connected, turn ignition switch to On position. SRS indicator lamp should light for approximately six seconds. If lamp does not light or remains on longer than six seconds, A SYSTEM MALFUNCTION IS INDICATED. Refer to Testing and Inspection / Procedures See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview e. Turn radio control to On. When word Code appears on display panel, enter five-digit theft protection code number. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Photo 90 Door Switch: Locations Photo 90 Rear Of Driver's Door Area (Right Front Similar) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Photo 90 > Page 8842 Door Switch: Locations Rear Door Switch Rear Of Left Door Area (Right Similar) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Description and Operation Fuel Gauge: Description and Operation When the ignition switch is in ON (II) or START (III), battery voltage is supplied through fuse 15 to the gauges in the gauge assembly. The Engine Coolant Temperature (ECT) gauge has two intersecting coils wound around a permanent magnet rotor. Voltage applied to the coils, through fuse 15, generates a magnetic field. The magnetic field, controlled by the coolant temperature sending unit, causes the rotor to rotate and the gauge needle to move. As the resistance in the sending unit varies, current through the gauge coils changes. The gauge needle moves toward the coil with the strongest magnetic field. The fuel gauge works the same way. The engine coolant temperature (ECT) sending unit's resistance varies from about 137 ohms at low engine temperature to between 30-46 ohms at high temperature (radiator fan running). The fuel gauge sending unit's resistance varies from about 2-5 ohms at full, to about 110 ohms at empty. When you turn the ignition switch OFF, the gauge remains at the last reading until you turn the ignition switch to ON (II) or START (III) again. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Description and Operation > Page 8846 Fuel Gauge: Testing and Inspection 1. Check No. 15 (10A) fuse in under dash fuse/relay box before testing. 2. Disconnect 3-P connector from fuel gauge sending unit. Fig. 4 Fuel Gauge Sending Unit 3. Connect voltmeter positive probe to (B) yellow/white terminal and negative probe to (A) black/white terminal, then turn ignition switch to On position, Fig. 4. 4. Voltage should be between 5-8 volts. 5. If voltage is not as specified, check the following: a. Check open yellow/white wire. b. Check blown fuse or poor ground. 6. Turn ignition switch On, then check as pointer of fuel gauge starts moving toward F mark. Turn ignition switch to Off before pointer reaches F mark on gauge dial. Failure to do so may damage fuel gauge. 7. If pointer of fuel gauge does not move, replace gauge. 8. If gauge is satisfactory, inspect fuel gauge and sending unit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Specifications Air Bag(s) Arming and Disarming: Specifications Component .......................................................................................................................................... ....................................................... Torque/Ft. Lbs. Dash Sensor Mounting Bolts .............................. .............................................................................................................................................................. .. 16 Driver Side Air Bag Assembly To Steering Wheel Bolts ................................................................................................................................................. 7.2 Passenger Side Air Bag Mounting Nuts & Bolts .................................................................................. ............................................................................. 7.2 SRS Unit Mounting Bolts ................................. .............................................................................................................................................................. .. 7.2 Steering Wheel To Column Steering Shaft Nut .......................................................................... ....................................................................................... 36 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Specifications > Page 8851 Air Bag(s) Arming and Disarming: Service Precautions 1. On models with 3-P SRS connectors, install red short connectors on air bags prior to disconnecting any part of SRS wiring harness. 2-P SRS connectors automatically short when disconnected. 2. Always use test harnesses. Do not use test probes directly on component connector pins or wires. 3. When connecting any test harnesses, push connectors straight in until secure. Do not bend connector pins. 4. Always keep red short connector on air bag connector when harness is disconnected. 5. Always store air bag assembly with pad surface facing upward. 6. Do not attempt to disassemble air bag assembly. 7. An air bag that has been deployed cannot be repaired or reused. 8. Keep air bag assembly free of oil and grease. 9. Do not expose air bag assembly to temperatures above 212°F. 10. Do not use SRS components from another vehicle. Always install new replacement components. 11. Do not paint air bag assembly to correct cosmetic flaws. It must be replaced. 12. Inspect all components prior to installation. Do not install any that appear to have been improperly handled or stored or that show any signs of damage. 13. When repairing vehicle, system should be disarmed as outlined under Technician Safety Information. 14. When performing service procedures, do not expose sensors or wiring or other SRS components to heat guns, welding or spray guns. 15. SRS wiring should not be spliced, soldered or repaired. 16. Use only special digital multimeter tool No. KS-AHM-32-003, or equivalent, digital multimeter with 0.0 mA or smaller output when switched to lowest ohmmeter range to inspect system. Analog or testers with higher outputs can damage circuits or cause accidental air bag deployment and, if equipped, seat belt pretensioner activation. 17. Do not bump SRS unit whenever ignition is turned On, or has been Off for less than three minutes. Unwanted deployment could result. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Specifications > Page 8852 Air Bag(s) Arming and Disarming: Service and Repair The Supplemental Restraint System (SRS) must be disarmed prior to disconnecting any electrical connectors or servicing any system components or items located near SRS electrical connectors. SRS electrical wiring can be identified by its yellow outer protective coating. To disarm the SRS, proceed as follows: 1. Obtain five-digit radio theft protection code number. 2. Disconnect battery ground cable, then the positive cable. Fig. 1 Driver Air Bag Disarming 3. After disconnecting cables, wait at least three minutes with ignition turned Off before disconnecting any SRS electrical connectors. This will allow air bag system back-up circuit capacitor to discharge. 4. Remove steering wheel access panel and disconnect electrical connector located between air bag and cable reel, Fig. 1 5. Remove glove compartment and access panel. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Specifications > Page 8853 Fig. 4 Passenger Air Bag Disarming 6. Disconnect front passenger air bag 3-P connector from SRS main harness and connect red short connector, Fig. 4. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Specifications > Page 8854 Fig. 12 Fuse Panel/SRS Connector 7. Using thin blade screwdriver, lift SRS to under-instrument panel fuse connector lid, Fig. 12, then press tab down and slide connector out. 8. Reverse procedure to reactivate system, noting following: a. Slide harness electrical connector onto fuse panel connections until it clicks, then close connector lid. b. Ensure all red short connectors have been removed and placed in their holders. c. Prior to connecting battery ground and positive cables, ensure all supplemental restraint system electrical connectors have been properly connected. d. After battery cables have been connected, turn ignition switch to On position. SRS indicator lamp should light for approximately six seconds. If lamp does not light or remains on longer than six seconds, A SYSTEM MALFUNCTION IS INDICATED. Refer to Testing and Inspection / Procedures See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview e. Turn radio control to On. When word Code appears on display panel, enter five-digit theft protection code number. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Description and Operation Key Reminder Switch: Description and Operation Battery voltage is supplied at all times to the seat belt reminder/key-ON beeper circuit in the integrated control unit. When you turn ON the ignition key switch the integrated control unit senses ground. If you open the driver's door, the door switch closes, causing the beeper to sound until the door is closed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Required Lamp/Indicator > Component Information > Service and Repair Maintenance Required Lamp/Indicator: Service and Repair If equipped with maintenance reminder flag: After completing the required service, the maintenance flags may be reset by inserting the ignition key into the appropriate slot, on the instrument below the indicator flag. When the ignition key is inserted into the slot, the indicator flag should change to green. If equipped with maintenance reminder lamp: 1. Turn off the engine. 2. Press and hold the select/reset button(s) on the instrument panel, then turn the ignition switch ON (Position II). 3. Hold the button(s) for at least 10 seconds, until the indicator resets. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Locations > Page 8864 Malfunction Indicator Lamp: Testing and Inspection When the Malfunction Indicator Lamp (MIL) has been reported on, do the following: 1. Connect the Service Check Connector terminals with a jumper wire as shown. (The 2P Service Check Connector is located under the dash on the passenger side of the car.) Turn the ignition switch on. 2. Note the Diagnostic Trouble Code (DTC): The MIL indicates a code by the length and number of blinks. The MIL can indicate simultaneous component problems by blinking separate codes, one after another. Codes I through 9 are indicated by individual short blinks. Codes 10 through 48 are indicated by a series of long and short blinks. The number of long blinks equals the first digit, the number of Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Description and Operation Odometer: Description and Operation When the ignition switch is in ON (II) or START (III), battery voltage is supplied through fuse 15 to the gauges in the gauge assembly. The odometer and speedometer drive circuits receive pulses from the Vehicle Speed Sensor (VSS). The pulse rate increases as the car accelerates. The frequency and duration of these input pulses are measured and displayed by the speedometer, odometer and tripmeter. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Warning Lamp/Indicator: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 8872 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 8873 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 8874 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 8875 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 8876 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 8877 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 8878 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 8879 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 8880 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 8881 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 8882 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 8883 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 8884 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 8885 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 8886 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 8887 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 8888 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 8889 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 8890 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 8891 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 8892 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 8893 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 8894 Oil Pressure Warning Lamp/Indicator: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 8895 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 8896 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 8897 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 8898 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 8899 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 8900 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 8901 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 8902 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 8903 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 8904 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 8905 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 8906 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 8907 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 8908 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 8909 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 8910 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 8911 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 8912 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 8913 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 8914 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 8915 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 8916 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 8917 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 8918 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 8919 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 8920 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 8921 Oil Pressure Indicator System Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations > Parking Brake Switch Parking Brake Warning Switch: Locations Parking Brake Switch Below Rear Console Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations > Parking Brake Switch > Page 8926 Parking Brake Warning Switch: Locations Parking Pin Switch Below Center Console Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions Seat Belt Reminder Lamp: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8931 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8932 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8933 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8934 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8935 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8936 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8937 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8938 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8939 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8940 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8941 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8942 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8943 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8944 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8945 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8946 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8947 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8948 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8949 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8950 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8951 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8952 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8953 Seat Belt Reminder Lamp: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8954 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8955 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8956 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8957 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8958 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8959 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8960 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8961 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8962 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8963 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8964 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8965 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8966 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8967 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8968 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8969 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8970 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8971 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8972 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8973 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8974 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8975 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8976 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8977 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8978 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8979 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8980 Seat Belt And Ignition Key Reminders Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Page 8981 Seat Belt Reminder Lamp: Description and Operation With the ignition switch in ON (II) or START (III), battery voltage is applied to the seat belt reminder light. When the seat belt is not buckled the seat belt reminder/key-ON beeper circuit in the integrated control unit senses ground through the closed seat belt switch. The seat belt reminder light flashes ON and OFF for five seconds. The reminder light and beeper will go OFF when the seat belt is buckled or the timer circuit deactivates them. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Photo 90 Door Switch: Locations Photo 90 Rear Of Driver's Door Area (Right Front Similar) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Photo 90 > Page 8987 Door Switch: Locations Rear Door Switch Rear Of Left Door Area (Right Similar) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Description and Operation Key Reminder Switch: Description and Operation Battery voltage is supplied at all times to the seat belt reminder/key-ON beeper circuit in the integrated control unit. When you turn ON the ignition key switch the integrated control unit senses ground. If you open the driver's door, the door switch closes, causing the beeper to sound until the door is closed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Parking Brake Switch Parking Brake Warning Switch: Locations Parking Brake Switch Below Rear Console Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Parking Brake Switch > Page 8995 Parking Brake Warning Switch: Locations Parking Pin Switch Below Center Console Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Description and Operation Speedometer Head: Description and Operation When the ignition switch is in ON (II) or START (III), battery voltage is supplied through fuse 15 to the gauges in the gauge assembly. The odometer and speedometer drive circuits receive pulses from the Vehicle Speed Sensor (VSS). The pulse rate increases as the car accelerates. The frequency and duration of these input pulses are measured and displayed by the speedometer, odometer and tripmeter. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Tachometer Connector > Component Information > Locations Tachometer Connector: Locations Left Rear Corner Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Description and Operation Temperature Gauge: Description and Operation When the ignition switch is in ON (II) or START (III), battery voltage is supplied through fuse 15 to the gauges in the gauge assembly. The Engine Coolant Temperature (ECT) gauge has two intersecting coils wound around a permanent magnet rotor. Voltage applied to the coils, through fuse 15, generates a magnetic field. The magnetic field, controlled by the coolant temperature sending unit, causes the rotor to rotate and the gauge needle to move. As the resistance in the sending unit varies, current through the gauge coils changes. The gauge needle moves toward the coil with the strongest magnetic field. The fuel gauge works the same way. The engine coolant temperature (ECT) sending unit's resistance varies from about 137 ohms at low engine temperature to between 30-46 ohms at high temperature (radiator fan running). The fuel gauge sending unit's resistance varies from about 2-5 ohms at full, to about 110 ohms at empty. When you turn the ignition switch OFF, the gauge remains at the last reading until you turn the ignition switch to ON (II) or START (III) again. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Description and Operation > Page 9006 Temperature Gauge: Testing and Inspection 1. Check No. 15 (10A) fuse in under dash fuse/relay box before testing. Fig. 1 Engine Coolant Temperature Unit 2. Ensure ignition switch is in Off position, then disconnect yellow/green wire from coolant temperature sending unit, Fig. 1, and ground it with a jumper wire. 3. Turn ignition switch to On position. 4. Check as needle of coolant temperature gauge starts moving toward H mark. Turn ignition switch to Off position before pointer reaches H mark on gauge dial. Failure to do so may damage gauge. 5. If pointer of gauge does not move, check the following: a. Blown fuse in under dash fuse/relay box. b. Open in yellow/green wire, yellow or red wire. c. If fuse and wiring are satisfactory, replace coolant temperature gauge. 6. If gauge is satisfactory, inspect sending unit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Locations Temperature Sensor (Gauge): Locations Right Front Of Engine. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Locations Transmission Shift Position Indicator Lamp: Locations When the ignition switch is in ON (II) or START (III), battery voltage is applied to the A/T gear position indicator through fuse 15. The A/T gear position switch provides a ground for each shift lever position. As an input is grounded, its indicator light comes on. When the headlight switch is in PARK or HEAD, voltage is applied through the RED/BLK wire to the dimming circuit in the A/T gear position indicator. The illumination intensity is varied by the dash lights brightness controller through the RED return wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions Transmission Shift Position Indicator Lamp: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9015 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9016 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9017 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9018 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9019 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9020 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9021 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9022 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9023 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9024 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9025 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9026 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9027 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9028 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9029 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9030 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9031 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9032 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9033 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9034 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9035 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9036 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9037 Transmission Shift Position Indicator Lamp: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9038 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9039 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9040 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9041 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9042 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9043 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9044 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9045 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9046 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9047 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9048 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9049 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9050 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9051 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9052 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9053 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9054 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9055 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9056 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9057 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9058 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9059 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9060 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9061 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9062 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9063 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9064 A/T Gear Position Indicator Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations Backup Lamp Switch: Locations Right Front Of Engine Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions Brake Lamp: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9074 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9075 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9076 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9077 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9078 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9079 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9080 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9081 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9082 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9083 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9084 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9085 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9086 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9087 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9088 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9089 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9090 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9091 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9092 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9093 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9094 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9095 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9096 Brake Lamp: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9097 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9098 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9099 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9100 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9101 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9102 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9103 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9104 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9105 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9106 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9107 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9108 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9109 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9110 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9111 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9112 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9113 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9114 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9115 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9116 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9117 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9118 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9119 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9120 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9121 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9122 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9123 Brake Lights- Sedan Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Service and Repair Brake Light Switch: Service and Repair 1. Disconnect wiring at switch. 2. Loosen locknut and remove switch. 3. Reverse procedure to install. Allow 0.039-0.196 inch (1-5 mm) brake pedal freeplay. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions Cargo Lamp: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9131 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9132 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9133 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9134 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9135 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9136 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9137 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9138 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9139 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9140 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9141 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9142 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9143 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9144 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9145 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9146 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9147 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9148 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9149 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9150 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9151 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9152 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9153 Cargo Lamp: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9154 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9155 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9156 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9157 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9158 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9159 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9160 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9161 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9162 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9163 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9164 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9165 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9166 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9167 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9168 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9169 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9170 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9171 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9172 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9173 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9174 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9175 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9176 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9177 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9178 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9179 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9180 Trunk/Cargo Area Light Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Service and Repair Center Mounted Brake Lamp: Service and Repair Hatchback: 1. Remove the access panel and two screws, then pull out the high mount brake light. Coupe/Sedan: 1. Open the trunk lid and disconnect the 2-P connector from the high mount brake light. 2. Remove the two screws and two nuts, then remove the high mount brake light from the rear shelf. 3. Install the high mount brake light in the reverse order of removal. Clean the rear window glass before installing the light. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Locations Daytime Running Lamp Control Unit: Locations Daytime Running light Relay/Control Unit Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Locations > Page 9188 Daytime Running Lamp Control Unit: Testing and Inspection Input Test Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Locations > Page 9189 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions Dome Lamp: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9194 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9195 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9196 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9197 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9198 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9199 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9200 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9201 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9202 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9203 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9204 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9205 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9206 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9207 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9208 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9209 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9210 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9211 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9212 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9213 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9214 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9215 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9216 Dome Lamp: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9217 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9218 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9219 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9220 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9221 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9222 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9223 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9224 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9225 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9226 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9227 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9228 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9229 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9230 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9231 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9232 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9233 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9234 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9235 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9236 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9237 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9238 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9239 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9240 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9241 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9242 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9243 Ceiling Light Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Photo 90 Door Switch: Locations Photo 90 Rear Of Driver's Door Area (Right Front Similar) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Photo 90 > Page 9248 Door Switch: Locations Rear Door Switch Rear Of Left Door Area (Right Similar) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Behind Dash, Right Of Steering Column Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Flasher Relay > Component Information > Locations Hazard Flasher Relay: Locations Behind Left Side Of Dash Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions Headlamp Switch: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9262 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9263 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9264 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9265 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9266 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9267 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9268 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9269 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9270 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9271 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9272 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9273 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9274 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9275 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9276 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9277 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9278 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9279 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9280 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9281 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9282 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9283 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9284 Headlamp Switch: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9285 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9286 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9287 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9288 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9289 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9290 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9291 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9292 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9293 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9294 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9295 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9296 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9297 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9298 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9299 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9300 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9301 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9302 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9303 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9304 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9305 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9306 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9307 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9308 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9309 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9310 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9311 Headlamp Switch: Electrical Diagrams Headlight Switch (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9312 Headlight Switch (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9313 Headlight Switch (Part 3 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Page 9314 Headlamp Switch: Service and Repair 1. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. 2. Disconnect battery ground cable. 3. Remove dashboard lower cover. 4. Remove steering column upper and lower covers. 5. Disconnect switch electrical connectors. 6. Remove two switch attaching screws, then slide switch assembly out of housing. 7. Reverse procedure to install. 8. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations Horn Relay: Locations Behind Left Side Of Dash - Photo 62 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Testing and Inspection Horn Switch: Testing and Inspection CAUTION: All SRS wire harnesses are covered with yellow insulation. Before you disconnect any part of an SRS wire harness, connect the short connectors. Whenever the ignition switch ON (II), or has been turned OFF for less than three minutes, be careful not to bump the SRS unit, the airbags could accidentally deploy and cause damage or injuries. NOTE: The original radio has a coded theft protection circuit. Be sure to get the customer's code number before, - disconnecting the battery. - removing the No.32 (7.5 A) fuse from the under hood fuse/relay box. - removing the radio. After service, reconnect power to the radio and turn it on. When the word "CODE" is displayed, enter the customer's 5~digit code to restore radio operation. 1. Disconnect both the negative cable and positive cable from the banery, and wait at least three minutes. 2. Make sure the wheels are turned straight ahead. 3. Remove the access panel below the driver's airbag, then remove the short connector (RED) from the panel. 4. Disconnect the 3-P connector between the driver's 'airbag and cable reel, then connect the short connector (RED) on the airbag side of the connector. 5. Remove the glove box and access panel. 6. Disconnect the 3-P connector between the front passenger's airbag and the SRS main harness, then connect the short connector (RED) on the airbag side of the connector. 7. Remove the dashboard lower cover and knee bolster. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Testing and Inspection > Page 9322 8. Disconnect the cable reel harness 6-P connector from the SRS main harness, then connect Test Harness C only to the cable reel harness. 9. Check for continuity between the No.3 terminal and body ground with the horn switch pressed. There should be continuity. 10. Remove the two TORX® bolts using a TORX® T30 bit, then remove the driver's airbag assembly. 11. Check for continuity between the horn switch positive terminal and the steering column shaft with the horn switch pressed. If there is continuity. - With cruise control: Test the set/resume switch. If the switch is OK, replace the cable reel. - Without cruise control: Replace the cable reel. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Testing and Inspection > Page 9323 If there is no continuity; - Remove the steering wheel and the four screws, then remove the steering wheel cover. Replace the faulty horn switch. 12. Reinstall the steering wheel. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions License Plate Lamp: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9328 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9329 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9330 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9331 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9332 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9333 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9334 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9335 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9336 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9337 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9338 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9339 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9340 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9341 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9342 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9343 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9344 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9345 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9346 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9347 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9348 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9349 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9350 License Plate Lamp: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9351 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9352 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9353 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9354 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9355 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9356 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9357 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9358 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9359 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9360 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9361 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9362 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9363 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9364 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9365 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9366 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9367 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9368 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9369 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9370 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9371 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9372 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9373 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9374 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9375 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9376 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9377 License Plate Lamp: Electrical Diagrams License, Parking, And Taillights Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9378 Taillights And License Lights Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations Daytime Running Lamp Control Unit: Locations Daytime Running light Relay/Control Unit Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations > Page 9383 Daytime Running Lamp Control Unit: Testing and Inspection Input Test Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations > Page 9384 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Behind Dash, Right Of Steering Column Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Locations Hazard Flasher Relay: Locations Behind Left Side Of Dash Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Behind Left Side Of Dash - Photo 62 Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Locations Turn Signal Relay: Locations Behind Left Side Of Dash Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations Backup Lamp Switch: Locations Right Front Of Engine Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Service and Repair Brake Light Switch: Service and Repair 1. Disconnect wiring at switch. 2. Loosen locknut and remove switch. 3. Reverse procedure to install. Allow 0.039-0.196 inch (1-5 mm) brake pedal freeplay. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Testing and Inspection Combination Switch: Testing and Inspection Combination Light Switch / Test Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Testing and Inspection > Page 9407 CAUTION: All SRS wire harnesses are covered with yellow insulation. Before you disconnect any part of an SRS wire harness, connect the short connectors. Whenever the ignition switch is ON (II), or has been turned OFF for less than three minutes, be careful not to bump the SRS unit; the airbags could accidentally deploy and cause damage or injuries. 1. Remove the dashboard lower cover and steering column covers. 2. Disconnect the 4-P and 7-P connectors from the switch. 3. Check the connector terminals to be sure they are all making good contact. If the terminals are bent, loose, or corroded, repair them as necessary, and recheck the system. 4. Check for continuity between the terminals in each switch position according to the table. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Photo 90 Door Switch: Locations Photo 90 Rear Of Driver's Door Area (Right Front Similar) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Photo 90 > Page 9412 Door Switch: Locations Rear Door Switch Rear Of Left Door Area (Right Similar) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions Headlamp Switch: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9417 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9418 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9419 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9420 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9421 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9422 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9423 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9424 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9425 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9426 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9427 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9428 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9429 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9430 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9431 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9432 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9433 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9434 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9435 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9436 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9437 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9438 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9439 Headlamp Switch: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9440 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9441 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9442 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9443 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9444 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9445 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9446 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9447 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9448 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9449 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9450 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9451 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9452 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9453 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9454 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9455 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9456 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9457 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9458 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9459 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9460 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9461 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9462 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9463 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9464 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9465 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9466 Headlamp Switch: Electrical Diagrams Headlight Switch (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9467 Headlight Switch (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9468 Headlight Switch (Part 3 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 9469 Headlamp Switch: Service and Repair 1. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. 2. Disconnect battery ground cable. 3. Remove dashboard lower cover. 4. Remove steering column upper and lower covers. 5. Disconnect switch electrical connectors. 6. Remove two switch attaching screws, then slide switch assembly out of housing. 7. Reverse procedure to install. 8. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Testing and Inspection Horn Switch: Testing and Inspection CAUTION: All SRS wire harnesses are covered with yellow insulation. Before you disconnect any part of an SRS wire harness, connect the short connectors. Whenever the ignition switch ON (II), or has been turned OFF for less than three minutes, be careful not to bump the SRS unit, the airbags could accidentally deploy and cause damage or injuries. NOTE: The original radio has a coded theft protection circuit. Be sure to get the customer's code number before, - disconnecting the battery. - removing the No.32 (7.5 A) fuse from the under hood fuse/relay box. - removing the radio. After service, reconnect power to the radio and turn it on. When the word "CODE" is displayed, enter the customer's 5~digit code to restore radio operation. 1. Disconnect both the negative cable and positive cable from the banery, and wait at least three minutes. 2. Make sure the wheels are turned straight ahead. 3. Remove the access panel below the driver's airbag, then remove the short connector (RED) from the panel. 4. Disconnect the 3-P connector between the driver's 'airbag and cable reel, then connect the short connector (RED) on the airbag side of the connector. 5. Remove the glove box and access panel. 6. Disconnect the 3-P connector between the front passenger's airbag and the SRS main harness, then connect the short connector (RED) on the airbag side of the connector. 7. Remove the dashboard lower cover and knee bolster. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Testing and Inspection > Page 9473 8. Disconnect the cable reel harness 6-P connector from the SRS main harness, then connect Test Harness C only to the cable reel harness. 9. Check for continuity between the No.3 terminal and body ground with the horn switch pressed. There should be continuity. 10. Remove the two TORX® bolts using a TORX® T30 bit, then remove the driver's airbag assembly. 11. Check for continuity between the horn switch positive terminal and the steering column shaft with the horn switch pressed. If there is continuity. - With cruise control: Test the set/resume switch. If the switch is OK, replace the cable reel. - Without cruise control: Replace the cable reel. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Testing and Inspection > Page 9474 If there is no continuity; - Remove the steering wheel and the four screws, then remove the steering wheel cover. Replace the faulty horn switch. 12. Reinstall the steering wheel. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection Turn Signal Switch: Testing and Inspection Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Page 9478 CAUTION: All SRS wire harnesses are covered with yellow insulation. Before you disconnect any part of an SRS wire harness, connect the short connectors. Whenever the ignition switch is ON (II), or has been turned OFF for less than three minutes, be careful not to bump the SRS unit; the airbags could accidentally deploy and cause damage or injuries. 1. Remove the dashboard lower cover and steering column covers. 2. Disconnect the 4-P and 7-P connectors from the switch. 3. Check the connector terminals to be sure they are all making good contact. If the terminals are bent, loose, or corroded, repair them as necessary, and recheck the system. 4. Check for continuity between the terminals in each switch position according to the table. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Page 9479 Turn Signal Switch: Service and Repair 1. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. 2. Disconnect battery ground cable. 3. Remove dashboard lower cover. 4. Remove steering column upper and lower covers. 5. Disconnect switch electrical connectors. 6. Remove two switch attaching screws, then slide switch assembly out of housing. 7. Reverse procedure to install. 8. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions Tail Lamp: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9484 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9485 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9486 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9487 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9488 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9489 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9490 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9491 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9492 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9493 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9494 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9495 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9496 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9497 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9498 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9499 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9500 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9501 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9502 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9503 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9504 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9505 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9506 Tail Lamp: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9507 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9508 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9509 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9510 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9511 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9512 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9513 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9514 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9515 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9516 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9517 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9518 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9519 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9520 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9521 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9522 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9523 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9524 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9525 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9526 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9527 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9528 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9529 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9530 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9531 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9532 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9533 Tail Lamp: Electrical Diagrams License, Parking, And Taillights Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9534 Taillights And License Lights Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions Trunk Lamp: Diagram Information and Instructions Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9539 Circuit Schematics Component Locations Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9540 To see where a component or connector is located on the car, look up its photo number in the Component Location section. The photo will also tell you the color of the connector, and how many cavities it has. Component Locations If there is no photo number below or beside a connector, ground, or terminal number, look up that connector, ground, or terminal number in the appropriate Connector Identification Chart. The chart will tell you the color of a connector, how many cavities it has, where it's located, and what component or harness it connects to. Along with this chart you'll find an image giving illustration of the related harness. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9541 Fuse Details Schematics Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9542 Ground Distribution Schematics Alternate View Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9543 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share two ground points. Circuit Identification For In-Line and Fuse Box Connectors Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9544 Circuit Identification For In-Line And Fuse Box Connectors (Part 1 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9545 Circuit Identification For In-Line And Fuse Box Connectors (Part 2 Of 3) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9546 Circuit Identification For In-Line And Fuse Box Connectors (Part 3 Of 3) How to Use Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9547 In-Line-Connector Circuit Identification Use this chart to help diagnose multiple symptoms in separate circuits which could be caused by a single problem in a connector shared by those circuits. 1. Pick one of the multiple symptoms and look up the schematic for that circuit. 2. Make a list of all in-line-connectors in that schematic. 3. Then, in this chart, look up each connector on your list to see if circuits related to the other symptoms run through one of them. If they do, inspect that connector for the problem. Example: The horn, A/C, and the right headlight don't work. List all in-line-connectors in the horn circuit and check this chart. You find that C211 is common to the A/C circuit and the headlight circuit, so you inspect C211 and find the problem: bent terminals. Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9548 Power Distribution Schematics-From Battery To Ignition Switch, Fuses,and Relays From Battery to Ignition Switch, Fuses, and Relays Individual circuit schematics begin with a fuse. The first half of Power Distribution, however, shows the wiring "upstream" between the battery and the fuses. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9549 From Fuses to Relays and Components The second half of Power Distribution shows the wiring "From Fuses to Relays and Components." This can speed your troubleshooting by showing which circuits share fuses. If Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9550 Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9551 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9552 Key To Wiring Diagrams And Symbol Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9553 Key To Wiring Diagrams And Symbol Identification Components Components A solid border line means the entire component is shown. Components Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9554 A broken border line indicates that only part of the component is shown. Components The name of the component appears next to its upper right corner followed by notes about its function. Connectors The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. Connectors-"C" The connector cavity number is listed next to each terminal on the circuit schematic. The cavity/terminal shown here is #6. Connectors-"C" This means the connector connects directly to the component. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9555 Connectors-"C" This means the connector connects to a lead (pigtail) wired directly to the component. Connector This symbol represents one bus inside the cap of a junction connector. A junction connector cap contains several buses, but only the one affecting that circuit will be shown. The dots represent tabs on the bus that the wire terminals connect to. Remaining wires to the same bus are represented by a broken line. Diodes Diodes A rectifier diode works like a one way valve. It allows current to flow only in the direction of the arrow. Diodes A Zener diode blocks reverse current at normal voltages just like a rectifier diode. At high voltages, however, a Zener diode allows current to flow in reverse. Fuses Fuses This means power is supplied when the ignition switch is in ON (II). Ground - "G" Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9556 Ground This symbol means the end of the wire is attached (grounded) to the car frame or to a metal part connected to the frame. Each wire ground (G) is numbered for reference. Ground This ground symbol (dot and 3 lines) overlapping the component means the housing of the component is grounded to the car frame or to a metal part connected to the frame. Ground This symbol represents the bus inside a ground connector. The dots represent tabs on the bus that the wire terminals connect to. The ground symbol (large dot) is the connection between the bus and metal (grounded) part of the car. Shielding Shielding This represents RFI (Radio Frequency Interference) shielding around a wire. The shielding is always connected to ground. Splices Splices Splices are shown as a dot. Their location and the number of wires may vary depending on the harness manufacturer. Switches Switches Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9557 These switches move together; the broken straight line between them means they are mechanically connected. Switches Switches Other types of switches are controlled by a coil or a solid state circuit. Unless otherwise noted, all switches are shown in their normal (rest) position, with power OFF. Terminals - "T" Terminals Each "T" terminal (ring type) is numbered for reference and location. A "T" terminal is secured with a screw or bolt. Wire Color Abbreviations SYMBOLS The following abbreviations are used to identify wire colors in the circuit schematics: BLK ...................................................................................................................................................... .......................................................... black BLU ...................................................................................................................................................... ............................................................ blue BRN ..................................................................................................................................................... ......................................................... brown GRN ..................................................................................................................................................... .......................................................... green GRY ..................................................................................................................................................... ............................................................ gray LT BLU ................................................................................................................................................ .................................................... light blue LT GRN ............................................................................................................................................... .................................................. light green ORN ..................................................................................................................................................... ........................................................ orange PNK ..................................................................................................................................................... ............................................................ pink PUR ..................................................................................................................................................... .......................................................... purple RED ..................................................................................................................................................... .............................................................. red WHT .................................................................................................................................................... ........................................................... white YEL ...................................................................................................................................................... ........................................................ yellow Wires Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9558 Wires An wavy line at the end of a wire means the wire is broken and continues on another image. Wires Wire insulation can be one color, or one color with another color stripe (The second color is the stripe.) Wires This circuit continues on another image. (The arrow shows direction of current flow) To follow the RED/BLK wire in this example, you would turn to the next image(s) and look for the "Z" arrow. Wires This means the branch of the wire connects to another circuit. The arrow points to the name of the circuit branch where the wire continues. Wires A broken line means this part of the circuit is not shown; refer to the circuit listed for the complete schematic. Wires Where separate wires join, only the splice is shown; for details on the additional wiring, refer to the circuits listed. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9559 Wires Wire choices for options or different models are labeled and shown with a "choice" bracket. Wires The broken line shown perpendicular to both wires means both terminals are in connector C134. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9560 Symbols And Wire Color Code Identification Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9561 Trunk Lamp: Diagnostic Aids Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9562 Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9563 Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9564 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9565 Five-Step Troubleshooting And Test Equipment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9566 Test Equipment Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: ^ Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. ^ Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9567 While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. 2. Make sure multiple terminal connectors are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it clicks into place. CAUTION: ^ Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. ^ Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Short to Ground With Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or Digital Volt/Ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (ZERO), there is a short to ground in the wiring near that point. Short to Ground With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9568 Testing For a Short with A Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For A Short to Ground With A Test Light or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9569 Testing For A Short To Ground With A Test Light Or DVOM 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or Digital Volt/Ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes OFF, or the DVOM voltage drops to ZERO, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9570 Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Troubleshooting Tests: Testing For A Short With A Short Circuit Locator (Short Finder) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9571 Testing For Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a Digital Volt/Ohmmeter (DVOM), place it in the lowest "OHMS" range. 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (ZERO), means good continuity. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9572 Troubleshooting Tests: Testing For Short To Ground With A Self-Powered Test Light Or DVOM Testing For Voltage Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9573 Testing For Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a Digital Volt Ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For Voltage Drop Testing For Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the Digital Volt/Ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9574 Troubleshooting Tests: Testing For Voltage Drop And Testing For A Short To Ground With A Test Light Or DVOM Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9575 Troubleshooting Tests: Testing For Voltage And Testing For Continuity Voltage Check Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9576 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter set to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9577 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9578 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9579 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9580 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9581 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9582 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9583 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9584 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9585 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9586 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9587 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9588 Trunk/Cargo Area Light Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Testing and Inspection Combination Switch: Testing and Inspection Combination Light Switch / Test Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Testing and Inspection > Page 9593 CAUTION: All SRS wire harnesses are covered with yellow insulation. Before you disconnect any part of an SRS wire harness, connect the short connectors. Whenever the ignition switch is ON (II), or has been turned OFF for less than three minutes, be careful not to bump the SRS unit; the airbags could accidentally deploy and cause damage or injuries. 1. Remove the dashboard lower cover and steering column covers. 2. Disconnect the 4-P and 7-P connectors from the switch. 3. Check the connector terminals to be sure they are all making good contact. If the terminals are bent, loose, or corroded, repair them as necessary, and recheck the system. 4. Check for continuity between the terminals in each switch position according to the table. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Locations Turn Signal Relay: Locations Behind Left Side Of Dash Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection Turn Signal Switch: Testing and Inspection Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Page 9600 CAUTION: All SRS wire harnesses are covered with yellow insulation. Before you disconnect any part of an SRS wire harness, connect the short connectors. Whenever the ignition switch is ON (II), or has been turned OFF for less than three minutes, be careful not to bump the SRS unit; the airbags could accidentally deploy and cause damage or injuries. 1. Remove the dashboard lower cover and steering column covers. 2. Disconnect the 4-P and 7-P connectors from the switch. 3. Check the connector terminals to be sure they are all making good contact. If the terminals are bent, loose, or corroded, repair them as necessary, and recheck the system. 4. Check for continuity between the terminals in each switch position according to the table. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Page 9601 Turn Signal Switch: Service and Repair 1. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. 2. Disconnect battery ground cable. 3. Remove dashboard lower cover. 4. Remove steering column upper and lower covers. 5. Disconnect switch electrical connectors. 6. Remove two switch attaching screws, then slide switch assembly out of housing. 7. Reverse procedure to install. 8. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations Heated Glass Element Relay: Locations Right Rear Corner Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Windows and Glass > Rear Defogger > Rear Defogger Relay > Component Information > Locations Rear Defogger Relay: Locations Right Rear Corner Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Heated Glass Element Relay: Locations Right Rear Corner Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Rear Defogger Relay > Component Information > Locations Rear Defogger Relay: Locations Right Rear Corner Of Engine Compartment Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations Power Window Relay: Locations Behind Left Side Of Dash Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Locations Front Door Window Motor: Locations Middle Of Driver's Door (Right Front Similar) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Locations Rear Door Window Motor: Locations Front Of Left Rear Door (Right Similar) Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Locations > Page 9629 Rear Door Window Motor: Service and Repair Glass/Regulator Replacement 1. Remove: - Door panel - Plastic cover - Corner sash trim 2. Remove the mounting not and mounting bolt attaching the rear channel. 3. Carefully move the glass until you can see the glass mounting bolts, then remove them. Carefully pull the glass out through the window slot. NOTE: - Take care not to drop the glass inside the door. - Take care not to damage locations (A) of the glass run channel. 4. Peel the glass run channel Out of the rear channel, then remove the rear channel. NOTE: After installing the rear channel, make sure the glass run channel is not twisted. NOTE: To install, the glass run channel, fit it into the reat channel an shown. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Locations > Page 9630 5. Remove the two mounting bolts. Loosen the mounting bolt and three motor bolts. Disconnect the connector (power window model). Remove the regulator through the center hole in the door. 6. Grease all the sliding surfaces of the regulator where shown. Check that the regulator moves smoothly by connecting the regulator handle or a 12 V battery to the power window motor. 7. Installation is the reverse of the removal procedure. 8. Roll the glass up and down to see if it moves freely without binding. Also make sure that there is no clearance between the glass and glass run channel when the glass is closed. Adjust the position of the glass as necessary. 9. Attach the door harness to the door correctly. 10. When reinstalling the plastic cover, apply adhesive along the edge where necessary to maintain a contentious seal and prevent water leaks. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations Power Window Relay: Locations Behind Left Side Of Dash Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > System Information > Service and Repair Rear Door Window Glass: Service and Repair Glass/Regulator Replacement 1. Remove: - Door panel - Plastic cover - Corner sash trim 2. Remove the mounting not and mounting bolt attaching the rear channel. 3. Carefully move the glass until you can see the glass mounting bolts, then remove them. Carefully pull the glass out through the window slot. NOTE: - Take care not to drop the glass inside the door. - Take care not to damage locations (A) of the glass run channel. 4. Peel the glass run channel Out of the rear channel, then remove the rear channel. NOTE: After installing the rear channel, make sure the glass run channel is not twisted. NOTE: To install, the glass run channel, fit it into the reat channel an shown. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > System Information > Service and Repair > Page 9638 5. Remove the two mounting bolts. Loosen the mounting bolt and three motor bolts. Disconnect the connector (power window model). Remove the regulator through the center hole in the door. 6. Grease all the sliding surfaces of the regulator where shown. Check that the regulator moves smoothly by connecting the regulator handle or a 12 V battery to the power window motor. 7. Installation is the reverse of the removal procedure. 8. Roll the glass up and down to see if it moves freely without binding. Also make sure that there is no clearance between the glass and glass run channel when the glass is closed. Adjust the position of the glass as necessary. 9. Attach the door harness to the door correctly. 10. When reinstalling the plastic cover, apply adhesive along the edge where necessary to maintain a contentious seal and prevent water leaks. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair Rear Door Window Regulator: Service and Repair Glass/Regulator Replacement 1. Remove: - Door panel - Plastic cover - Corner sash trim 2. Remove the mounting not and mounting bolt attaching the rear channel. 3. Carefully move the glass until you can see the glass mounting bolts, then remove them. Carefully pull the glass out through the window slot. NOTE: - Take care not to drop the glass inside the door. - Take care not to damage locations (A) of the glass run channel. 4. Peel the glass run channel Out of the rear channel, then remove the rear channel. NOTE: After installing the rear channel, make sure the glass run channel is not twisted. NOTE: To install, the glass run channel, fit it into the reat channel an shown. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Page 9643 5. Remove the two mounting bolts. Loosen the mounting bolt and three motor bolts. Disconnect the connector (power window model). Remove the regulator through the center hole in the door. 6. Grease all the sliding surfaces of the regulator where shown. Check that the regulator moves smoothly by connecting the regulator handle or a 12 V battery to the power window motor. 7. Installation is the reverse of the removal procedure. 8. Roll the glass up and down to see if it moves freely without binding. Also make sure that there is no clearance between the glass and glass run channel when the glass is closed. Adjust the position of the glass as necessary. 9. Attach the door harness to the door correctly. 10. When reinstalling the plastic cover, apply adhesive along the edge where necessary to maintain a contentious seal and prevent water leaks. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > Customer Interest for Window Seal: > 00-021 > Feb > 00 > Windshield - Wind Noise (Whistle) Window Seal: Customer Interest Windshield - Wind Noise (Whistle) 00-021 February 1, 2000 Applies To: 1995-00 Civic - ALL Wind Whistle at the Top of the Windshield (Replaces 95-056, dated March 2, 1999) SYMPTOM A whistling or howling noise coming from the top, middle of the windshield at highway speeds. The molding may also be deformed or loose. PROBABLE CAUSE Vibration of the upper windshield molding. CORRECTIVE ACTION Apply sealant under the entire length of the upper windshield molding. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 824003 Flat Rate Time: 0.5 hour Failed Part: P/N 73150-S04-003 H/C 4779385 Defect Code: 056 Contention Code: B07 Template ID: 00-021A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REQUIRED MATERIALS 3M Black Super Silicone Sealant: (3M P/N 051135-08662) 3M General Purpose Adhesive Cleaner: (3M P/N 051135-08984) DIAGNOSIS Drive the car at highway speeds to verify the noise. If you hear the noise, and its frequency or volume changes when you push on the top of the windshield in front of the rear view mirror, go to REPAIR PROCEDURE. REPAIR PROCEDURE 1. Protect the roof by applying 2-inch-wide masking tape along the edge of the upper windshield molding, and around the corners. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > Customer Interest for Window Seal: > 00-021 > Feb > 00 > Windshield - Wind Noise (Whistle) > Page 9652 2. Pull the rear edge of the upper windshield molding away from the roof (use a cotter pin puller or similar tool), and apply a liberal amount of 3M Black Super Silicone Sealant underneath it. Apply sealant along the entire masked-off area. 3. Push on the molding to smooth it out and to form a good seal. 4. After five minutes, remove the masking tape. Clean up any excess sealant with 3M General Purpose Adhesive Cleaner. 5. To give the sealant time to cure, tell the customer not to wash the windshield for 24 hours. Disclaimer Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Seal: > 00-021 > Feb > 00 > Windshield - Wind Noise (Whistle) Window Seal: All Technical Service Bulletins Windshield - Wind Noise (Whistle) 00-021 February 1, 2000 Applies To: 1995-00 Civic - ALL Wind Whistle at the Top of the Windshield (Replaces 95-056, dated March 2, 1999) SYMPTOM A whistling or howling noise coming from the top, middle of the windshield at highway speeds. The molding may also be deformed or loose. PROBABLE CAUSE Vibration of the upper windshield molding. CORRECTIVE ACTION Apply sealant under the entire length of the upper windshield molding. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 824003 Flat Rate Time: 0.5 hour Failed Part: P/N 73150-S04-003 H/C 4779385 Defect Code: 056 Contention Code: B07 Template ID: 00-021A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REQUIRED MATERIALS 3M Black Super Silicone Sealant: (3M P/N 051135-08662) 3M General Purpose Adhesive Cleaner: (3M P/N 051135-08984) DIAGNOSIS Drive the car at highway speeds to verify the noise. If you hear the noise, and its frequency or volume changes when you push on the top of the windshield in front of the rear view mirror, go to REPAIR PROCEDURE. REPAIR PROCEDURE 1. Protect the roof by applying 2-inch-wide masking tape along the edge of the upper windshield molding, and around the corners. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Seal: > 00-021 > Feb > 00 > Windshield - Wind Noise (Whistle) > Page 9658 2. Pull the rear edge of the upper windshield molding away from the roof (use a cotter pin puller or similar tool), and apply a liberal amount of 3M Black Super Silicone Sealant underneath it. Apply sealant along the entire masked-off area. 3. Push on the molding to smooth it out and to form a good seal. 4. After five minutes, remove the masking tape. Clean up any excess sealant with 3M General Purpose Adhesive Cleaner. 5. To give the sealant time to cure, tell the customer not to wash the windshield for 24 hours. Disclaimer Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest for Windshield: > 00-021 > Feb > 00 > Windshield - Wind Noise (Whistle) Windshield: Customer Interest Windshield - Wind Noise (Whistle) 00-021 February 1, 2000 Applies To: 1995-00 Civic - ALL Wind Whistle at the Top of the Windshield (Replaces 95-056, dated March 2, 1999) SYMPTOM A whistling or howling noise coming from the top, middle of the windshield at highway speeds. The molding may also be deformed or loose. PROBABLE CAUSE Vibration of the upper windshield molding. CORRECTIVE ACTION Apply sealant under the entire length of the upper windshield molding. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 824003 Flat Rate Time: 0.5 hour Failed Part: P/N 73150-S04-003 H/C 4779385 Defect Code: 056 Contention Code: B07 Template ID: 00-021A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REQUIRED MATERIALS 3M Black Super Silicone Sealant: (3M P/N 051135-08662) 3M General Purpose Adhesive Cleaner: (3M P/N 051135-08984) DIAGNOSIS Drive the car at highway speeds to verify the noise. If you hear the noise, and its frequency or volume changes when you push on the top of the windshield in front of the rear view mirror, go to REPAIR PROCEDURE. REPAIR PROCEDURE 1. Protect the roof by applying 2-inch-wide masking tape along the edge of the upper windshield molding, and around the corners. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest for Windshield: > 00-021 > Feb > 00 > Windshield - Wind Noise (Whistle) > Page 9667 2. Pull the rear edge of the upper windshield molding away from the roof (use a cotter pin puller or similar tool), and apply a liberal amount of 3M Black Super Silicone Sealant underneath it. Apply sealant along the entire masked-off area. 3. Push on the molding to smooth it out and to form a good seal. 4. After five minutes, remove the masking tape. Clean up any excess sealant with 3M General Purpose Adhesive Cleaner. 5. To give the sealant time to cure, tell the customer not to wash the windshield for 24 hours. Disclaimer Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest for Windshield: > 95-056 > Sep > 97 > Body - Wind Whistle at the Top of the Windshield Windshield: Customer Interest Body - Wind Whistle at the Top of the Windshield Bulletin No. 95-056 Issue Date SEP 8, 1997 Model 1995-97 [NEW] CIVIC Applicable To ALL File Under BODY Wind Whistle at the Top of the Windshield (Supersedes 95-056, dated December 18, 1995) SYMPTOM A whistling or howling noise coming from the top, middle of the windshield at highway speeds. PROBABLE CAUSE Vibration of the upper windshield molding. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation number: 824003 Flat rate time: 0.5 hour Failed part: P/N 731 50-S04-003 H/C 4779385 Defect code: 056 Contention code: B07 Template ID: 97-001A Skill level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REQUIRED MATERIALS 3M Black Super Silicone Sealant: (3M P/N 051135-08662) 3M General Purpose Adhesive Cleaner: (3M P/N 051135-08984) DIAGNOSIS Drive the car at highway speeds to verity the noise. If you hear the noise, and its frequency or volume changes when you push on the top of the windshield in front of the rear view mirror, continue with the CORRECTIVE ACTION. CORRECTIVE ACTION Apply sealant under the entire length of the upper windshield molding. REPAIR PROCEDURE Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest for Windshield: > 95-056 > Sep > 97 > Body - Wind Whistle at the Top of the Windshield > Page 9672 1. Protect the roof by applying 2-inch-wide masking tape along the edge of the upper windshield molding, between the left and right roof moldings. 2. Pull the rear edge of the upper windshield molding away from the roof (use a cotter pin puller or similar tool), and apply a liberal amount of 3M Black Super Silicone Sealant underneath it. Apply sealant along the entire length of the upper windshield molding. 3. Push on the molding to smooth it out and to form a good seal. 4. Remove the masking tape, then clean up any excess sealant with 3M General Purpose Adhesive Cleaner. 5. To give the sealant time to cure, tell the customer not to wash the windshield for 24 hours. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 00-021 > Feb > 00 > Windshield - Wind Noise (Whistle) Windshield: All Technical Service Bulletins Windshield - Wind Noise (Whistle) 00-021 February 1, 2000 Applies To: 1995-00 Civic - ALL Wind Whistle at the Top of the Windshield (Replaces 95-056, dated March 2, 1999) SYMPTOM A whistling or howling noise coming from the top, middle of the windshield at highway speeds. The molding may also be deformed or loose. PROBABLE CAUSE Vibration of the upper windshield molding. CORRECTIVE ACTION Apply sealant under the entire length of the upper windshield molding. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 824003 Flat Rate Time: 0.5 hour Failed Part: P/N 73150-S04-003 H/C 4779385 Defect Code: 056 Contention Code: B07 Template ID: 00-021A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REQUIRED MATERIALS 3M Black Super Silicone Sealant: (3M P/N 051135-08662) 3M General Purpose Adhesive Cleaner: (3M P/N 051135-08984) DIAGNOSIS Drive the car at highway speeds to verify the noise. If you hear the noise, and its frequency or volume changes when you push on the top of the windshield in front of the rear view mirror, go to REPAIR PROCEDURE. REPAIR PROCEDURE 1. Protect the roof by applying 2-inch-wide masking tape along the edge of the upper windshield molding, and around the corners. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 00-021 > Feb > 00 > Windshield - Wind Noise (Whistle) > Page 9678 2. Pull the rear edge of the upper windshield molding away from the roof (use a cotter pin puller or similar tool), and apply a liberal amount of 3M Black Super Silicone Sealant underneath it. Apply sealant along the entire masked-off area. 3. Push on the molding to smooth it out and to form a good seal. 4. After five minutes, remove the masking tape. Clean up any excess sealant with 3M General Purpose Adhesive Cleaner. 5. To give the sealant time to cure, tell the customer not to wash the windshield for 24 hours. Disclaimer Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 95-056 > Sep > 97 > Body - Wind Whistle at the Top of the Windshield Windshield: All Technical Service Bulletins Body - Wind Whistle at the Top of the Windshield Bulletin No. 95-056 Issue Date SEP 8, 1997 Model 1995-97 [NEW] CIVIC Applicable To ALL File Under BODY Wind Whistle at the Top of the Windshield (Supersedes 95-056, dated December 18, 1995) SYMPTOM A whistling or howling noise coming from the top, middle of the windshield at highway speeds. PROBABLE CAUSE Vibration of the upper windshield molding. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation number: 824003 Flat rate time: 0.5 hour Failed part: P/N 731 50-S04-003 H/C 4779385 Defect code: 056 Contention code: B07 Template ID: 97-001A Skill level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REQUIRED MATERIALS 3M Black Super Silicone Sealant: (3M P/N 051135-08662) 3M General Purpose Adhesive Cleaner: (3M P/N 051135-08984) DIAGNOSIS Drive the car at highway speeds to verity the noise. If you hear the noise, and its frequency or volume changes when you push on the top of the windshield in front of the rear view mirror, continue with the CORRECTIVE ACTION. CORRECTIVE ACTION Apply sealant under the entire length of the upper windshield molding. REPAIR PROCEDURE Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 95-056 > Sep > 97 > Body - Wind Whistle at the Top of the Windshield > Page 9683 1. Protect the roof by applying 2-inch-wide masking tape along the edge of the upper windshield molding, between the left and right roof moldings. 2. Pull the rear edge of the upper windshield molding away from the roof (use a cotter pin puller or similar tool), and apply a liberal amount of 3M Black Super Silicone Sealant underneath it. Apply sealant along the entire length of the upper windshield molding. 3. Push on the molding to smooth it out and to form a good seal. 4. Remove the masking tape, then clean up any excess sealant with 3M General Purpose Adhesive Cleaner. 5. To give the sealant time to cure, tell the customer not to wash the windshield for 24 hours. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection Windshield Washer Switch: Testing and Inspection 1. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. 2. Remove steering column covers. 3. Disconnect 8-P and 6-P connectors from wiper switch. Fig. 9 Wiper/Washer Switch Continuity Chart 4. Check for continuity between terminals in each switch position according to table, Fig. 9. Replace switch as necessary. 5. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 9689 Windshield Washer Switch: Service and Repair 1. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. 2. Remove instrument panel lower cover. 3. Remove upper and lower steering column covers from steering column. 4. Disconnect 8-P and 6-P connectors from wiper switch. 5. Remove two attaching screws and slide wiper switch out of housing. 6. Reverse procedure to install. 7. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection Wiper Switch: Testing and Inspection 1. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. 2. Remove steering column covers. 3. Disconnect 8-P and 6-P connectors from wiper switch. Fig. 9 Wiper/Washer Switch Continuity Chart 4. Check for continuity between terminals in each switch position according to table, Fig. 9. Replace switch as necessary. 5. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 9693 Wiper Switch: Service and Repair 1. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. 2. Disconnect battery ground cable. 3. Remove dashboard lower cover. 4. Remove steering column upper cover. 5. Disconnect electrical connectors. 6. Remove wiper/washer switch attaching screws, then the switch. 7. Reverse procedure to install. 8. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations Windshield Washer Motor: Locations Inside Left Front Wheel Well Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations > Page 9697 Windshield Washer Motor: Testing and Inspection 1. Remove front bumper. 2. Disconnect 2-P connector from washer motor. 3. Test front and rear washer motor operation by connecting battery positive to positive (A) terminal of pump and battery negative to negative terminal (B) of pump. If pump fails to run smoothly, replace. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service and Repair Windshield Washer Pump: Service and Repair 1. Remove front bumper, then disconnect washer hose and 2-P connectors from front and rear washer motors. 2. Remove three mounting bolts and washer reservoir. 3. Reverse procedure to install. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair Windshield Washer Reservoir: Service and Repair 1. Remove front bumper, then disconnect washer hose and 2-P connectors from front and rear washer motors. 2. Remove three mounting bolts and washer reservoir. 3. Reverse procedure to install. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection Windshield Washer Switch: Testing and Inspection 1. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. 2. Remove steering column covers. 3. Disconnect 8-P and 6-P connectors from wiper switch. Fig. 9 Wiper/Washer Switch Continuity Chart 4. Check for continuity between terminals in each switch position according to table, Fig. 9. Replace switch as necessary. 5. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 9707 Windshield Washer Switch: Service and Repair 1. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. 2. Remove instrument panel lower cover. 3. Remove upper and lower steering column covers from steering column. 4. Disconnect 8-P and 6-P connectors from wiper switch. 5. Remove two attaching screws and slide wiper switch out of housing. 6. Reverse procedure to install. 7. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Rear Window Wiper Motor Wiper Motor: Locations Rear Window Wiper Motor Bottom Of Hatch Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Rear Window Wiper Motor > Page 9712 Wiper Motor: Locations Photo 25 Behind Left Side Of Air Scoop Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Front Wiper Motor Wiper Motor: Testing and Inspection Front Wiper Motor Fig. 13 Front Wiper Motor Connector Terminal Identification 1. Disconnect 5-P connector at wiper motor, Fig. 13. 2. Connect battery positive to D terminal and negative to B terminal. Motor should run smoothly at low speed. If it does not, replace motor. 3. Connect battery positive to D terminal and negative to A terminal. Motor should run smoothly at high speed. If it does not, replace motor. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Front Wiper Motor > Page 9715 Wiper Motor: Testing and Inspection Rear Wiper Motor 1. Remove hatch trim panel. Fig. 16 Rear Wiper Motor Connector Terminal Identification 2. Disconnect 4-P connector at wiper motor, Fig. 16. 3. Connect battery positive to No. 2 terminal and negative to No. 4 terminal. Motor should run smoothly. If it does not, repair or replace as necessary. Fig. 17 Rear Wiper Motor Continuity Chart 4. Check for continuity between terminals according to table, Fig. 17. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Front Wiper Motor Wiper Motor: Service and Repair Front Wiper Motor 1. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. 2. Disconnect battery ground cable. 3. Open hood and remove wiper arm retaining nuts and wiper arms. 4. Unsnap clips carefully with a screwdriver and remove air scoop complete with hood sealing rubber. 5. Disconnect wiring harness at motor. 6. Remove wiper linkage bolts, then the linkage assembly. 7. Remove mounting bolts and nut from wiper linkage, then remove wiper motor. 8. Reverse procedure to install. 9. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Front Wiper Motor > Page 9718 Wiper Motor: Service and Repair Rear Wiper Motor 1. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. 2. Disconnect battery ground cable. 3. Remove hatch trim cover. 4. Remove cover and wiper arm attaching nut, then the wiper arm. 5. Remove cap, nut and washers from wiper arm shaft. 6. Remove rubber seal from wiper arm shaft, then disconnect wiper motor electrical connector. 7. Remove three wiper motor attaching bolts and wiper motor. 8. Reverse procedure to install. 9. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. Honda Civic Sedan Workshop Manual (L4-1.5L SOHC (16 valve) (1995)) Honda Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection Wiper Switch: Testing and Inspection 1. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. 2. Remove steering column covers. 3. Disconnect 8-P and 6-P connectors from wiper switch. Fig. 9 Wiper/Washer Switch Continuity Chart 4. Check for continuity between terminals in each switch position according to table, Fig. 9. Replace switch as necessary. 5. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures.